Method and apparatus for dyeing garments

ABSTRACT

Described herein are apparatuses and methods for dyeing garments. An exemplary apparatus comprises a dye injection system configured to dispense concentrated liquid dye; a dyeing machine comprising a dyeing chamber configured for dyeing at least one garment in a dyebath; and a controller in communication with the dye injection system and the dyeing machine, wherein the controller is configured: to receive at least one garment parameter corresponding to the at least one garment; based at least in part on the at least one received garment parameter, cause the dye injection system to dispense a volume of concentrated liquid dye containing an amount of dyestuff that can be substantially absorbed by the at least one garment; and cause the dyeing machine to execute a dye cycle such that substantially all of the dyestuff in the dispensed concentrated liquid dye is absorbed by the at least one garment within the dyeing chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority from provisional PatentApplication Ser. No. 62/837,165, filed Apr. 22, 2019, and fromprovisional Patent Application Ser. No. 62/925,078, filed Oct. 23, 2019,each of which is incorporated herein by reference in its entirety.

BACKGROUND

In both industrial and commercial applications, known garment dyeingprocesses are expensive and time-consuming. In particular, existinggarment dyeing processes use large quantities of dye, water, salts, andother substances, which must be used and disposed of in order to apply adesired color to a garment. Conventional dyeing processes often requirethe use of a dye comprising a pre-mixed solution of dyestuff, water,salts, and other elements added to enhance the dye's compatibility witha garment, fabric, or fiber. The pre-mixed solution may be delivered toa dyeing machine, containing water, where a garment absorbs just aportion of dyestuff present in the dyebath, leaving a resultant effluentin the dyeing machine.

Various processes have evolved to include complex, expensive methods offiltering and/or treating the water post-dyeing, but the contaminantsthat remain in the water prohibit the remaining water from beingreusable in a flexible, variable color dyeing process. Indeed, evencontemporary dyeing processes are unable to avoid the excessive,inefficient consumption of raw materials.

In an industry driven by the needs of the consumer, adapting to evolvingtrends or seasonal preferences requires a flexibility and an efficiencythat is missing from the existing garment dyeing processes. Thelarge-batch manufacturing processes that currently define the industryare not only wasteful, but they cannot support rapid transitions incustomer color preference. Present garment dyeing processes are definedby rigid systems incapable of accommodating variability or customizationof, for example, garment colors and/or patterns without sacrificingefficiency, quality, and/or resources. Furthermore, existing garmentdyeing processes have long been defined by the inefficient use of excesswater, dye, and other wasteful byproducts, requiring significant effortsto control pollution and environmental impact.

Accordingly, a need exists in the art for an agile, flexible method ofdyeing garments that can be responsive to the rapid changes in productdemand in a financially and environmentally efficient manner.

BRIEF SUMMARY

Various embodiments described herein relate to apparatuses and methodsfor dyeing garments. Various embodiments are directed to an apparatusfor dyeing garments, the apparatus comprising: a dye injection systemconfigured to dispense concentrated liquid dye; a dyeing machinecomprising a dyeing chamber configured for dyeing at least one garmentin a dyebath, wherein the dyebath comprises concentrated liquid dyereceived from the dye injection system and a volume of solvent; and acontroller in communication with the dye injection system and the dyeingmachine, wherein the controller is configured to: receive at least onegarment parameter corresponding to the at least one garment; based atleast in part on the at least one received garment parameter, cause thedye injection system to dispense a volume of concentrated liquid dyethat contains an amount of dyestuff that can be substantially absorbedby the at least one garment; and cause the dyeing machine to execute adye cycle such that substantially all of the dyestuff in the dispensedvolume of concentrated liquid dye is absorbed by the at least onegarment within the dyeing chamber.

In various embodiments, the dyebath within the dyeing chamber may besubstantially free of Sodium Chloride, Sodium Sulphate, and alkalinecontent throughout the dye cycle. In various embodiments, the dyeingmachine may be configured to execute the dye cycle with the dye bath atsubstantially ambient room temperature. In various embodiments, the atleast one garment parameter may comprise a weight of the at least onegarment. In certain embodiments, the apparatus may further comprise aweight sensor. Further, in various embodiments, the controller may befurther configured to receive the weight of the at least one garmentfrom the weight sensor. In various embodiments, the dyeing machine maybe configured to maintain the volume of solvent within a substantiallyclosed-loop system. In certain embodiments, the apparatus may furthercomprise at least one holding tank in fluid communication with thedyeing chamber, wherein the at least one holding tank may be configuredfor holding the volume of solvent in between dyeing cycles.

In various embodiments, the volume of solvent may comprise water. Invarious embodiments, the concentrated liquid dye may comprise dyestuffand water. In various embodiments, the dye injection system may comprisea plurality of concentrated liquid dye cartridges, each of the pluralityof concentrated liquid dye cartridges being configured store a volume ofconcentrated liquid dye having a unique dye color. In certainembodiments, the plurality of concentrated liquid dye cartridges of thedye injection system may comprise between seven and twelve concentratedliquid dye cartridges. In various embodiments, the controller is furtherconfigured to cause the dye injection system to dispense the volume ofconcentrated liquid dye that contains the amount of dyestuff that can besubstantially absorbed by the at least one garment based at least inpart on the user-selected desired garment color. In various embodiments,the controller may be further configured to, based at least in part on auser-selected desired garment color, cause one or more of a plurality ofconcentrated liquid dye cartridges to dispense concentrated liquid dyeinto the dyeing chamber to produce the user-selected desired garmentcolor during the dye cycle. In certain embodiments, the apparatus mayfurther comprise a user interface configured to enable a user to selectthe desired garment color. In various embodiments, the dispensed volumeof concentrated liquid dye contains an amount of dyestuff that issubstantially less than or equal to a dyestuff absorption capacity ofthe at least one garment

Various embodiments are directed to a method of dyeing garments, themethod comprising: providing an apparatus for dyeing garmentscomprising: a dye injection system configured to dispense concentratedliquid dye; and a dyeing machine comprising a dyeing chamber configuredfor dyeing at least one garment in a dyebath; receiving at least onegarment and a volume of solvent in the dyeing chamber of the dyeingmachine; receiving at least one garment parameter corresponding to theat least one garment; based at least in part on the at least onereceived garment parameter, dispensing, via the dye injection system, avolume of concentrated liquid dye that contains an amount of dyestuffthat can be substantially absorbed by the at least one garment so as tocreate a dyebath, wherein the dyebath comprises the concentrated liquiddye dispensed from the dye injection system and the volume of solvent;and executing a dye cycle such that substantially all of the dyestuff inthe dispensed volume of concentrated liquid dye is absorbed by the atleast one garment within the dyeing chamber.

In various embodiments, the dyestuff in the dispensed volume ofconcentrated liquid dye is configured such that a resultant dyebathdisposed within the dyeing chamber of the dyeing machine upon executionof the dye cycle is at least substantially free of additive dyeingenhancement agents, and wherein executing the dye cycle comprisesmaintaining the dyebath at a substantially ambient temperature. Invarious embodiments, the at least one garment parameter comprises agarment weight corresponding to a weight of the at least one garment.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent or application file contains at least one drawing executed incolor. Copies of this patent or patent application publication withcolor drawing(s) will be provided by the Office upon request and paymentof the necessary fee.

Reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a schematic diagram of an exemplary dyeing apparatus.

FIG. 2 schematically illustrates an exemplary apparatus in accordancewith various embodiments.

FIG. 3 illustrates a flow diagram of an exemplary method of dyeing agarment in accordance with some example embodiments described herein.

FIG. 4 illustrates a flow diagram of an exemplary method of cationizinga garment in accordance with some example embodiments described herein.

FIGS. 5 a-5 b illustrate an exemplary garment cationized in accordancewith some example embodiments described herein.

FIGS. 6 a-6 b illustrate an exemplary garment dyed in accordance withsome example embodiments described herein.

FIGS. 7 a-7 b illustrate an exemplary garment dyed in accordance withsome example embodiments described herein.

FIG. 8 shows an experimental exemplary garment dyed in accordance withsome example embodiments described herein.

FIG. 9 illustrates an exemplary garment dyed in accordance with someexample embodiments described herein.

FIG. 10 shows various experimental exemplary garment portions dyed inaccordance with some example embodiments described herein.

DETAILED DESCRIPTION

The following description should be read with reference to the drawingswherein like reference numerals indicate like elements throughout theseveral views. The detailed description and drawings show severalembodiments which are meant to be illustrative of the disclosure. Itshould be understood that any numbering of disclosed features (e.g.,first, second, etc.) and/or directional terms used in conjunction withdisclosed features (e.g., front, back, top, bottom, side, and the like)are relative terms indicating illustrative relationships between thepertinent features.

It should be understood at the outset that although illustrativeimplementations of one or more aspects are illustrated below, thedisclosed assemblies, systems, and methods may be implemented using anynumber of techniques, whether currently known or not yet in existence.The disclosure should in no way be limited to the illustrativeimplementations, drawings, and techniques illustrated below, but may bemodified within the scope of the appended claims along with their fullscope of equivalents. While values for dimensions of various elementsare disclosed, the drawings may not be to scale.

The words “example,” or “exemplary,” when used herein, are intended tomean “serving as an example, instance, or illustration.” Anyimplementation described herein as an “example” or “exemplaryembodiment” is not necessarily preferred or advantageous over otherimplementations.

Overview

Described herein are methods and apparatuses for efficiently dyeinggarments that enable on-demand dyeing of garments in a substantiallyclosed-loop system. As will be appreciated from the description herein,various disclosed methods and apparatuses minimize waste andenvironmental impact. In an example implementation, a method andapparatus for dyeing garments may be utilized to dye garments on ascalable level (e.g., individual garments, small batches of garments, orlarge batches of garments). It should be understood that while variousembodiments described herein are directed to dyeing a garment, themethod and apparatus embodiments disclosed herein may be configured todye materials other than a garment (e.g., garment thread, yarn, wovensheets, any colorable fabric, or any other dye absorbent material).

In various embodiments, the method and apparatus use a predeterminedamount of a concentrated liquid dye—which, as described in greaterdetail herein, is void of various salts (e.g., Sodium Chloride, SodiumSulphate) and various other additives (e.g., soda ash, caustic, etc.)that are used in conventional dyeing processes. In such embodiments, theamount of concentrated liquid dye used is based on a garment parametercorresponding to the dyestuff absorption capacity of the garment (e.g.,the weight (or mass) of the fiber in the garment being dyed).

In such an exemplary implementation, the concentrated liquid dye mayconsist primarily of dyestuff and water, and may be dispensed directlyinto a dyeing machine. Within the dyeing machine, the dispensedconcentrated liquid dye is mixed with the dyeing solvent (e.g., water)at the point of dyeing to create a dyebath. A cationized garment in thedyeing machine may then absorb all of the dyestuff present in thedyebath (e.g., as a result of the weight-based injection of apredetermined amount of concentrated liquid dye). This process therebyleaves a resultant water void of anything but trace contaminants (e.g.,less than 5% contaminant concentration), rendering the resultant watersuitable for direct reuse in subsequent dyeing processes.

In various implementations, prior to reuse in the dyeing process, theremaining water may be processed using a filtration system, wherein asupplemental material, for example, cutting scraps from the creation ofthe garments, may be used to absorb any remaining volume of dyestuffwithin the dyebath. Such an exemplary system configuration allowssubsequent garments to be dyed with different dye color combinationsusing the same solvent, thereby enabling a dyeing process that utilizesa closed-loop water system and maintains the flexibility to dye garmentsdifferent colors in subsequent uses. An exemplary closed-loop watersystem as described herein may not only eliminate the massive waterconsumption that defines many traditional dyeing processes, but it alsomay eliminate the need for bulky water holding tanks, effectivelyminimizing the footprint of a dyeing apparatus.

In one example implementation, the amount of water present within thesystem may become irrelevant to the dyeing process, as long as thegarments are able to completely absorb the dyestuff, as the relationshipdriving dye absorption is the ratio of volume of dyestuff to weight ofthe garment. The complex chemical calculation required by traditionaldyeing processes in order to ensure optimal dyeing conditions isdrastically simplified by effectively eliminating the liquor-to-goodsratio as a variable to be tuned. As described herein, such an exemplaryconfiguration enables a simplified dyeing process, wherein, given aselected resultant garment color, the amount of concentrated liquid dyeinjected into the dyeing machine is based solely on the weight of thegarment being dyed.

In various applications, due to the minimized physical and environmentalfootprint and a simplified chemical calculus, the improved dyeingprocess as disclosed herein may enable a garment to be dyed a selectedcolor on-demand, based on user input in either a retail or manufacturingsetting.

Further described herein are systems and methods for efficiently dyeinga patterned garment that enable on-demand patterned cationizing ofgarments and create a predetermined pattern of dye when the garments aresubsequently subjected to a dyeing process. As will be appreciated fromthe description herein, the disclosed methods are substantiallyautomated, agile, and minimize waste and environmental impact. In anexample implementation, a method for dyeing a patterned garment may beutilized on a scalable level (e.g., individual garments, small batchesof garments, or large batches of garments). It should be understood thatthe methods for dyeing a patterned garment as described herein may beutilized independent of, or in combination with, the disclosed methodsand apparatuses for dyeing garments, as described herein.

In various embodiments, a method of dyeing a patterned garment maycomprise selectively applying a cationic treatment agent to one or moreareas on a garment to create localized cationic patterns. The cationictreatment agent may be applied to the garment using various techniques,such as, for example screen printing, spraying, and/or digital printing.In such circumstances, when the garment is subsequently subjected to adyeing operation, substantially all of a volume of dyestuff absorbed bythe garment may be absorbed by those areas of the garment to which thecationic treatment agent has been applied, while the untreated garmentareas maintain the original garment color. Further, the depth of shadeof the colored pattern may be selectively varied by changing one or moreof: the volume of dyestuff used in the dyeing operation, the dye cycleruntime, and the concentration of cationic treatment agent applied atthe garment area (“cationic concentration”). As described herein,selectively applying a localized volume of cationic pretreatment tocreate a colored pattern on a garment eliminates the need for subsequentreductive processes which are often required to achieve a desiredpattern. Thus, as described herein, the present invention reduces boththe amount of effluent discharged during the dyeing process, and theproduction time associated with manufacturing a patterned garment.

Apparatus for Dyeing

As illustrated in FIG. 1 , an exemplary dyeing apparatus 100 maycomprise an apparatus housing 101, dyeing machine 110, a dye injectionsystem 120, a filtration system 130, one or more holding tanks 140, anda controller 200.

In various embodiments the dyeing machine 110 may comprise a commercialdyeing vessel configured to receive one or more cationized garments. Thedyeing machine 110 may be further configured to receive a volume ofsolvent and a volume of concentrated liquid dye directly dispensed fromthe dye injection system 120 positioned adjacent the dyeing machine 110.The dyeing machine 110 may be positioned on top of a supporting surfacesuch as, for example, a floor. In various embodiments, the dyeingmachine 110 may be configured to execute a dye cycle. The dye cyclecomprises mixing one or more volumes of concentrated liquid dyedispensed directly into the dyeing machine and dyeing a garment withinthe dyeing machine 110. As described herein, the dyeing machine 110 maybe configured to execute a dye cycle such that substantially all of thedyestuff in a volume of concentrated liquid dye dispensed into thedyeing machine is absorbed by the garment (or garments) within thedyeing machine. In various embodiments, the dyeing machine may comprisea machine configured for beam dyeing, yarn dyeing, jigger dyeing, winchdyeing, soft flow dyeing or airflow dyeing processes.

In various embodiments, the dyeing machine 110 may comprise a dyeingchamber configured for dyeing at least one garment in a dyebath. Thedyeing chamber may be configured to receive at least one garment and adyebath (e.g., a volume of solvent, such as water, and a volume ofconcentrated liquid dye). For example, the dyeing chamber may comprisean internal chamber disposed within the housing 101 of the dyeingmachine 110. In the illustrated embodiment, the dyeing machine'sinternal chamber is an inner cylindrical chamber 111. In someembodiments, inner cylindrical chamber 111 of the dyeing machine 110 maybe configured to have a volumetric capacity of, for example, between 10and 10,000 liters and rotate with a speed between, for example, 1 and100 RPM during a dye cycle. In various embodiments, the rotation speedof the dyeing machine's inner cylindrical chamber 111 may be constant ormay be varied throughout a dye cycle to facilitate relative motionbetween a garment and a dyebath in order to encourage engagement of thegarment with the volume of dyestuff present within the dyebath.

In various embodiments, the dyebath may comprise a volume of solvent anda volume of concentrated liquid dye. Accordingly, the dyebath mayconsist essentially of a volume of solvent and a volume of concentratedliquid dye throughout a dye cycle. In embodiments in which theconcentrated liquid dye itself comprises water and dyestuff, the dyebathmay likewise comprise a volume of water and an amount of dyestuff(dispensed via the concentrated liquid dye).

In various embodiments, the dyeing machine 110 may be configuredmaintain the dyebath at a substantially ambient temperature during a dyecycle. For example, depending on the classification of the dyes used(e.g., Reactive, Direct, or Acid) the dyeing machine may be configuredmaintain a dyebath temperature of between 18 and 95 degrees Celsiusthroughout a dye cycle. As described herein, by operating a dye cycle ata substantially ambient temperature, the dyeing machine 110 may avoidhaving to heat the dyebath to temperatures substantially higher thanambient temperature (e.g., 20 degrees Celsius), thereby drasticallyreducing the amount of energy consumed during the dyeing process incomparison to traditional dyeing processes. The dyeing machine 110 maybe configured to execute a dye cycle for a runtime lasting a period oftime that is related to the weight of the garment in the dyeing machine,the depth of the shade of the resultant garment color, and theexhaustion of the dyestuff into the fiber of the garment. In anexemplary implementation, a dye cycle may comprise a length of time ofbetween 20 and 60 minutes (e.g., between 30 and 45 minutes).

In various embodiments, the dyeing machine 110 may be fluidly connectedto a filtration system 130. In such an exemplary embodiment, after thecompletion of a dye cycle, the dyeing machine 110 may be configured todispense the dyebath—comprising a volume of solvent and any residualvolume of dyebath not absorbed by the garment—such that the dyebath maybe directed to the filtration system 130. Further, the dyeing machine110 may be fluidly connected to one or more holding tanks 140. Invarious embodiments, before the execution of a dye cycle, the dyeingmachine 110 may be configured to receive a volume of at leastsubstantially clean solvent from either the one or more holding tanks140 or directly from the filtration system 130. In various embodiments,the volume of solvent received by the dyeing machine 110 may besubstantially equal to or less than the volumetric capacity of thedyeing machine 110. Further, in various embodiments, the dyeing machine110 may comprise one or more liquid flow meters positioned at a solventinlet and/or a solvent outlet, each respectively configured to measurethe volume of water being received by and dispensed by the dyeingmachine 110. The dyeing machine 110 may further comprise a liquid levelindicator configured to measure a volume of water present within thedyeing machine 110.

In various embodiments, the dyeing machine may be configured to washand/or dry the garment after a dye cycle has completed and the remainingdyebath has been dispensed from the dyeing machine 110. In variousembodiments, the garment may be washed one or more times in order towash away a volume of hydrolyzed dye from the garment. In variousembodiments, the number of times a garment is washed may depend on thedepth of the shade of the user-selected garment output color.

In various embodiments, the dyeing machine 110 may further comprise aweight sensor (e.g., a scale) to determine the weight of the garment tobe dyed. In various embodiments, the weight sensor may be eitherincorporated within the dyeing machine 110 or included as a stand-alonecomponent. In various embodiments, the weight sensor may be configuredto communicate the measured weight to the controller 200.

As just one example, the dyeing machine 110 may comprise a Flainox NRG,E-Color and Essiccatoi machines, or any other suitable dyeing machinehaving a configuration as described herein.

In various embodiments, the dye injection system 120 may be positionedadjacent the dyeing machine 110 such that one or more volumes ofconcentrated liquid dye may be dispensed from the dye injection system120 directly into the dyeing machine 110. The dye injection system 120may comprise a dye housing 121 configured to house each of the one ormore volumes of concentrated liquid dye and the corresponding dispensemachinery. As described herein, concentrated liquid dye may comprise anamount of dyestuff and a volume of solvent, and, based on thecomposition of the dyestuff, may be associated with a unique color. Forexample, the concentrated liquid dye used in various embodiments mayconsist only of water and dyestuff (e.g., chromophore). In variousembodiments, the concentrated liquid dye may be void of variousadditives traditionally used to enhance the percentage of dye uptake inthe dyeing process, such as, for example, various added salt content(e.g., Sodium Chloride, Sodium Sulphate), alkaline content (e.g., SodiumHydroxide, Sodium Carbonate), or other contaminant. In certainembodiments, the concentrated liquid may include—in addition to waterand dyestuff—one or more lifespan enhancing agents (e.g., SodiumTripolyphosphate and/or an antimicrobial agent) configured to expand theuseful lifespan of the concentrated liquid dye.

In various embodiments, the one or more volumes of concentrated liquiddyes may be respectively stored in one or more concentrated liquid dyecartridges 122. The dye housing 121 may be configured to secure andposition each of the one or more concentrated liquid dye cartridges 122such that they may be fluidly connected to a respective dispense header123. In various embodiments, the dye injection system 120 may comprisebetween one and twenty (e.g., between seven and twelve) concentrated dyecartridges 122, each housing a concentrated liquid dye associated with arespective concentrated liquid dye color. In various embodiments, theone or more corresponding dye dispense headers 123 may be configured todirect the flow of a volume of concentrated liquid dye dispensed from aconcentrated liquid dye cartridge 122 into the dyeing machine 110. Theexemplary apparatus illustrated in FIG. 1 comprises twelve concentratedliquid dye cartridges 122 and twelve corresponding dye dispense headers123.

As described herein, the dye injection system 120 may be configured tofacilitate the dispense of one or more volumes of concentrated liquiddye into the dyeing machine so as to produce a garment of a pre-selectedresultant garment color. In various embodiments, each of theconcentrated liquid dyes may be respectively associated with aconcentrated liquid dye color. As non-limiting examples, variousconcentrated liquid dyes may include Orange One, Orange Two, Yellow One,Yellow Two, Blue One, Turquoise Three, Red Two, and/or the like. One ormore concentrated liquid dyes may be dispensed at various ratios suchthat the total collective concentrated liquid dye dispensed into thedyeing machine 110 may comprise a dye input color configured to producea resultant garment color pre-selected by a user. As non-limitingexamples, various resultant garment colors may include exemplaryproprietary colors with manufacturer specified characteristics (e.g.,referred to herein for convenience as Light Orange, Bold Orange, PaleYellow, Dark Yellow, Dark Blue, Light Turquoise, Dark Red and the like).In various embodiments, each resultant garment color may be associatedwith a depth of shade (e.g., Light Orange having a lighter depth ofshade than Bold Orange). In various embodiments, the percentageallocation of the respective concentrated liquid dye colors (i.e., theratio of the respective concentrated liquid dyes dispensed) defines thedye input color and affects the shade of the resultant garment color.Further, as described herein, a depth of shade of a resultant garmentcolor may correspond, at least in part, to a total amount of dyestuff(per unit weight or other garment parameter) required to produce agarment having the resultant garment color. For example, in an exemplarycircumstance wherein a first resultant garment color has a bolder depthof shade than a lighter depth of shade of a second resultant garmentcolor, a greater total amount of dyestuff (e.g., per unit weight ofgarment dyed) may be required in order to produce a garment comprisingthe first resultant garment color.

Further, in various embodiments, the volume of each of the respectiveconcentrated liquid dyes dispensed (i.e., the amount of the totalcollective concentrated liquid dye) may be based at least in part on agarment parameter corresponding to the at least one garment in thedyeing machine 110. In various embodiments, a garment parameter may be acharacteristic of a garment (or group of garments) that defines, atleast in part, the capacity of the garment for absorbing a volume ofdyestuff (e.g., the dyestuff absorption capacity of a garment). In otherwords, a garment parameter may be a feature or characteristic of thegarment (or group of garments) known to correspond to a dyestuffabsorption capacity for the garment (e.g., the total amount of dyestuffthe garment or group of garments is capable of absorbing from adyebath). As non-limiting examples, a garment parameter may be: agarment weight; a garment size (e.g., for a known garment type where thegarment size corresponds to a known absorption capacity); a garment SKU;and any garment value corresponding to a known dyestuff absorptioncapacity. For example, in various embodiments, the volume of each of therespective concentrated liquid dyes dispensed (i.e., the amount of thetotal collective concentrated liquid dye) may proportionally correspondto the weight of the garment in the dyeing machine 110 (e.g., such thatto produce a garment of a resultant garment color, the amount of totalcollective concentrated liquid dye dispensed from a dye injection systemdepends on the weight of the garment). For example, the amount ofdyestuff within the total collective volume concentrated liquid dyedispensed in order to dye a garment may be less than the dyestuffabsorption capacity of the garment.

Further, for example, in various embodiments, the volume of each of therespective concentrated liquid dyes dispensed (i.e., the amount of thetotal collective concentrated liquid dye) may correspond to the cationicconcentration of the garment in the dyeing machine 110. In variousembodiments, a maximum volume of concentrated liquid dye able to beabsorbed by a garment may be known to produce a resultant garment colorof full depth. This maximum volume of absorbable concentrated liquid dyealso defines the maximum volume of concentrated liquid dye that may bedispensed into the system for dyeing of the garment. As will beappreciated from the description herein, the maximum volume ofabsorbable concentrated liquid dye is dependent on the concentration ofthe concentrated liquid dye (e.g., the amount of dyestuff per unitvolume of solvent comprising the concentrated liquid dye) and the weightof the garment to be dyed (e.g., heavier garments being capable ofabsorbing more dyestuff than lighter garments of the same material).

In various embodiments, a lesser amount of dye may be injected into themachine in order to affect the depth of the shade of dye input color(e.g., to produce a lighter shade of the dye input color). As anon-limiting example, in various embodiments, a first resultant garmentcolor corresponding to a lighter depth of shade may require a lesseramount of dyestuff (per unit weight of the garment) to be dispensed intothe machine (e.g., via one or more volumes of concentrated liquid dye)than a second resultant garment color corresponding to a bolder depth ofshade. Accordingly, in various embodiments, the resultant garment colormay be a function of both the percentage allocation of the respectiveconcentrated liquid dye colors and the amount of concentrated liquid dyedispensed into the system (relative to the weight of the garment beingdyed).

The controller 200 may be configured to calculate both the appropriateratio and the appropriate volume of each of the respective concentratedliquid dyes to be dispensed based on input received by a user at a userinterface. For example, based at least in part on at least one garmentparameter, the controller may be configured to cause the dye injectionsystem to dispense a volume of concentrated liquid dye that contains anamount of dyestuff that can be substantially absorbed by the at leastone garment (i.e., which is substantially less than or equal to thedyestuff absorption capacity of the at least one garment). The dyeinjection system 120 may be configured to receive communications fromthe controller 200 and accordingly dispense the appropriate amount ofeach of the concentrated liquid dyes into the dyeing machine 110.

In various embodiments, the one or more volumes of concentrated liquiddye may be dispensed from the respective dispense headers 123 directlyinto the dyeing machine 110. In various other embodiments, the volumesof concentrated liquid dye may be dispensed from the respective dispenseheaders 123 into a mixing tank to facilitate sufficient mixing beforebeing further dispensed into the dyeing machine 110. In furtherembodiments, the one or more volumes of concentrated liquid dye may bedispensed from the respective dispense headers 123 and into a commondelivery conduit configured to receive the one or more volumes ofconcentrated liquid dye and deliver each volume to the dyeing machine110. In such embodiments, the one or more volumes of concentrated liquiddye may be present within the delivery conduit at substantially the sametime so as to facilitate a mixing of the respective volumes within thedelivery conduit. In certain embodiments, the delivery conduit mayfurther comprise mixing hardware present within the delivery conduitconfigured to further facilitate mixing by creating a tortious fluidflow. The delivery conduit may also be fluidly connected to aconcentrated liquid dye collection funnel or any other suitablecollection mechanism configured to capture each of the one or moredispensed volumes of concentrated liquid dye and direct them into thedelivery conduit.

As just one example, the dye injection system 120 may comprise aColorService SRL JIT automated dyestuff dosing machine, a DatacolorAutolab TF dispense system, or any other suitable dye injection systemhaving a configuration as described herein.

In various embodiments, the filtration system 130 may be configured toreceive a dyebath from a dyeing machine 110 after a dye cycle has beencompleted and remove the entirety of a residual volume of dyestuffremaining in the dyebath. In various embodiments, the filtration system130 may comprise a reservoir and a supplemental material. The reservoirmay be configured to retain the volume of dyebath dispensed from thedyeing machine 110. In various embodiments, the reservoir may be madefrom a non-absorbent inert material such as, for example, polypropylene.In various embodiments, the supplemental material of the filtrationsystem 130 may be configured to be submerged into the volume of thedyebath so as to interact with and absorb the entirety of a residualvolume of dyestuff. In one exemplary apparatus, the supplementalmaterial may comprise excess fabric, fiber, yarn, cotton and may becationized to facilitate dyestuff absorption. For example, thesupplemental material may be sewn into a polypropylene container (i.e.,a “tea-bag”) for the purposes of facilitating the supplementalmaterial's interaction with the contents of the dyebath and maintainingcontrol of the supplemental material during its submersion.Alternatively, in various embodiments, the filtration system 130 maycomprise a vessel with one or more strainers configured to remove theentirety of the residual volume of dyestuff from the dyebath. Further,in an alternative environment, the filtration system 130 may notcomprise a reservoir, but, instead, may comprise only a supplementalmaterial configured to be submerged in a dyebath after the dye cycle hasbeen completed but before the dyebath has been dispensed from the dyeingmachine 110. In various embodiments, the filtration system 130 mayfurther comprise a sensor configured to detect when the dyebath has beensufficiently cleaned by measuring the transmission of light through avolume of the dyebath to quantify the presence of any remainingimpurities.

In various embodiments, after the resultant volume of dyestuff has beenremoved from the dyebath, the filtration system 130 may be configured todispense the volume of substantially clean solvent into one or moreholding tanks 140 to be stored. Alternatively, the filtration system 130may be configured to dispense the volume of substantially clean solventback into the dyeing machine 110 for use in the subsequent dye cycle.

As just one example, the filtration system 130 may comprise an AxiumProcess Dyehouse Effluent Treatment and Water Reuse System, or any othersuitable filtration system having a configuration as described herein.

In various embodiments, the one or more holding tanks 140 may compriseone or more containers configured to store excess solvent present withinthe closed-loop system of the dyeing apparatus 100 as described herein.In various embodiments, each of the one or more holding tanks 140 mayhold a volume of solvent that is substantially equal to or larger than avolume of solvent that may be used to define a dyebath. In variousembodiments, the one or more holding tanks 140 may be configured toreceive a volume of substantially clean solvent from either thefiltration system 130 or the dyeing machine 110. In various embodiments,the one or more holding tanks 140 may be configured for holding a volumeof solvent between dyeing cycles. The one or more holding tanks 140 maybe further configured to dispense a volume of solvent into the dyeingmachine 110. The one or more holding tanks 140 may not be present invarious embodiments of the garment dyeing apparatus 100 as describedherein.

As just one example, the one or more holding tanks 140 may comprise anysuitable commercially available liquid holding tank having aconfiguration as described herein.

As illustrated in FIG. 2 , an exemplary controller 200 may compriseprocessing circuitry 202, memory 204, input-output circuitry 206,communications circuitry 208, dyeing machine circuitry 210, dyeinjection system circuitry 220, power circuitry 214, and user interfacecircuitry 216. The exemplary controller 200 may be configured to executethe operations described above with respect to FIG. 1 and below withrespect to FIG. 3 . In various embodiments, the controller 200 may bedisposed within the apparatus housing 101 or may exist external to theapparatus housing as a distinct component electronically connected tothe various other components that comprise the apparatus as describedherein. Although some of these components 202-216 are described withrespect to their functional capabilities, it should be understood thatthe particular implementations necessarily include the use of particularhardware to implement such functional capabilities. It should also beunderstood that certain of these components 202-216 may include similaror common hardware. For example, two sets of circuitry may both leverageuse of the same processor, network interface, storage medium, or thelike to perform their associated functions, such that duplicate hardwareis not required for each set of circuitry.

The use of the term “circuitry” as used herein with respect tocomponents of the dyeing apparatus 100 therefore includes particularhardware configured to perform the functions associated with respectivecircuitry described herein. Of course, while the term “circuitry” shouldbe understood broadly to include hardware, in some embodiments,circuitry may also include software for configuring the hardware. Forexample, in some embodiments, “circuitry” may include processingcircuitry, storage media, network interfaces, input-output devices, andother components. In some embodiments, other elements of the controller200 may provide or supplement the functionality of particular circuitry.For example, the processing circuitry 202 may provide processingfunctionality, memory 204 may provide storage functionality, andcommunications circuitry 208 may provide network interfacefunctionality, among other features.

In some embodiments, the processing circuitry 202 (and/or co-processoror any other processing circuitry assisting or otherwise associated withthe processor) may be in communication with the memory 204 via a bus forpassing information among components of the apparatus. The memory 204may be non-transitory and may include, for example, one or more volatileand/or non-volatile memories. For example, the memory 204 may be anelectronic storage device (e.g., a computer readable storage medium). Inanother example, the memory 204 may be a non-transitorycomputer-readable storage medium storing computer-executable programcode instructions that, when executed by a computing system, cause thecomputing system to perform the various operations described herein. Thememory 204 may be configured to store information, data, content,signals applications, instructions (e.g., computer-executable programcode instructions), or the like, for enabling the controller 200 tocarry out various functions in accordance with example embodiments ofthe present disclosure. For example, the memory 204 may be configured tostore garment type data; garment weight data; concentrated liquid dyecartridge fill status data; dyestuff color combination data;concentrated liquid dye data (e.g., dyestuff concentrations); dye cycleconfiguration techniques; concentrated liquid dye dispense calculations;dyestuff configuration data; dye injection techniques; energyconsumption data; water consumption data; monitored data; any othersuitable data or data structures; or any combination or combinationsthereof. It will be understood that the memory 204 may be configured tostore partially or wholly any electronic information, data, datastructures, embodiments, examples, figures, processes, operations,techniques, algorithms, instructions, systems, apparatuses, methods, orcomputer program products described herein, or any combination thereof.

The processing circuitry 202 may be embodied in a number of differentways and may, for example, include one or more processing devicesconfigured to perform independently. Additionally, or alternatively, theprocessing circuitry 202 may include one or more processors configuredin tandem via a bus to enable independent execution of instructions,pipelining, multithreading, or a combination thereof. The use of theterm “processing circuitry” may be understood to include a single coreprocessor, a multi-core processor, multiple processors internal to theapparatus, remote or “cloud” processors, or a combination thereof.

In an example embodiment, the processing circuitry 202 may be configuredto execute instructions stored in the memory 204 or otherwise accessibleto the processing circuitry 202. Alternatively, or additionally, theprocessing circuitry 202 may be configured to execute hard-codedfunctionality. As such, whether configured by hardware or softwaremethods, or by a combination of hardware with software, the processingcircuitry 202 may represent an entity (e.g., physically embodied incircuitry) capable of performing operations according to an embodimentof the present disclosure while configured accordingly. As anotherexample, when the processing circuitry 202 is embodied as an executor ofprogram code instructions, the instructions may specifically configurethe processor to perform the operations described herein when theinstructions are executed.

In some embodiments, the controller 200 may include input-outputcircuitry 206 that may, in turn, be in communication with processingcircuitry 202 to provide output to the user and, in some embodiments, toreceive input such as a command provided by the user. The input-outputcircuitry 206 may comprise a user interface, such as a graphical userinterface (GUI), and may include a display that may include a web userinterface, a GUI application, a mobile application, a client device, orany other suitable hardware or software. In some embodiments, theinput-output circuitry 206 may also include a keyboard, a mouse, ajoystick, a display device, a display screen, a touch screen, touchareas, soft keys, a microphone, a speaker (e.g., a buzzer), a lightemitting device (e.g., a red light emitting diode (LED), a green LED, ablue LED, a white LED, an infrared (IR) LED, an ultraviolet (UV) LED, ora combination thereof), or other input-output mechanisms. The processingcircuitry 202, input-output circuitry 206 (which may utilize theprocessing circuitry 202), or both may be configured to control one ormore functions of one or more user interface elements throughcomputer-executable program code instructions (e.g., software, firmware)stored in a non-transitory computer-readable storage medium (e.g.,memory 204). Input-output circuitry 206 is optional and, in someembodiments, the controller 200 may not include input-output circuitry.For example, where the controller 200 does not interact directly withthe user, the controller 200 may generate user interface data fordisplay by one or more other devices with which one or more usersdirectly interact and transmit the generated user interface data to oneor more of those devices. For example, the controller 200, using userinterface circuitry 216, may generate user interface data for display byone or more display devices and transmit the generated user interfacedata to those display devices.

The communications circuitry 208 may be any device or circuitry embodiedin either hardware or a combination of hardware and software that isconfigured to receive or transmit data from or to a network or any otherdevice, circuitry, or module in communication with the controller 200.In this regard, the communications circuitry 208 may include, forexample, a network interface for enabling communications with a wired orwireless communication network. For example, the communicationscircuitry 208 may include one or more network interface cards, antennae,buses, switches, routers, modems, and supporting hardware and/orsoftware, or any other device suitable for enabling communications via anetwork. In some embodiments, the communication interface may includethe circuitry for interacting with the antenna(s) to cause transmissionof signals via the antenna(s) or to handle receipt of signals receivedvia the antenna(s). These signals may be transmitted or received by thecontroller 200 using any of a number of Internet, Ethernet, cellular,satellite, or wireless technologies, such as IEEE 802.11, Code DivisionMultiple Access (CDMA), Global System for Mobiles (GSM), UniversalMobile Telecommunications System (UMTS), Long-Term Evolution (LTE),Bluetooth® v1.0 through v5.0, Bluetooth Low Energy (BLE), infraredwireless (e.g., IrDA), ultra-wideband (UWB), induction wirelesstransmission, Wi-Fi, near field communications (NFC), WorldwideInteroperability for Microwave Access (WiMAX), radio frequency (RF),RFID, or any other suitable technologies.

The dyeing machine circuitry 210 includes hardware components designedor configured to receive, process, generate, and transmit data relatedto the dyeing machine's execution of a dye cycle and interaction withother components of the dyeing apparatus 100, such as dye cyclecommencement and completion signals. In various embodiments, the dyeingmachine circuitry 210 may be configured to receive a dye cyclecommencement command based on signals transmitted from, for example, theinput-output circuitry 206. Further, the dyeing machine circuitry 210may be configured to communicate with the memory 204 and processcommands related to dye cycle configuration (e.g., run time, dyebathtemperature). In various embodiments, the dyeing machine circuitry 210may be configured to transmit a dye cycle completion signal to one ormore circuitry components of the controller 200.

The dye injection system circuitry 212 includes hardware componentsdesigned or configured to receive, process, generate, and transmit data,such as color composition data and concentrated liquid dye dispensedata. In various embodiments, the dye injection system circuitry 212 maybe configured to receive a user-selected resultant garment color signalfrom the input-output circuitry 206. In various embodiments, the dyeinjection system circuitry 212 may be configured to communicate with thememory 204 and retrieve the concentrated liquid dye ratio dataassociated the user-selected resultant garment color indicated in thesignal received. The concentrated liquid dye ratio data may comprise theratios of each of the respective concentrated liquid dyes to bedispensed (i.e., the recipe) in order to produce a dye input colorassociated with a resultant garment color. For example, in variousembodiments, the concentrated liquid dye ratio data may comprisedyestuff concentrations of each of the concentrated liquid dyes (i.e.,the ratio of dyestuff to water within the concentrated liquid dye), aswell as ratios of each of the respective dyestuffs to be dispensed inorder to produce a resultant garment color. In various embodiments, thememory 204 may store concentrated liquid dye ratio data for each of theresultant garment colors available to be selected. In variousembodiments, the concentrated liquid dye ratio data may comprise one ormore lookup tables associated with each of the available resultantgarment colors (e.g., correlating the appropriate ratio of concentratedliquid dye colors and/or the appropriate total amount of dye to bedispensed in order to produce a garment of the resultant garment color).By way of non-limiting example, an exemplary look up table may include aratio of various concentrated liquid dye colors corresponding to, forexample, various proprietary resultant garment color, as follows:

Proprietary Concentrated Liquid Dye Parts per Color Components WholeDark Blue Red Two 1 (5.56%) Blue Two 15 (83.33%) Turquoise One 2(11.21%) Light Red Yellow One 2 (28.57%) Orange One 1 (14.29%) Red Two 4(51.14%)

Further, the dye injection system circuitry 212 may be configured toreceive at least one garment parameter corresponding to at least onegarment from one or more components of the controller 200. For example,the dye injection system circuitry 212 may be configured to receive agarment weight signal from the dyeing machine circuitry 210 (e.g., froma weight sensor) and/or the input-output circuitry 206 (e.g., auser-selected garment weight signal). Alternatively, or additionally,the dye injection system circuitry 212 may be configured to receive auser-selected garment type signal and/or a garment count signal, whereinthe dye injection system circuitry 212 may be further configured toidentify a garment weight corresponding to the garment type and/orgarment count selected by a user. In such an exemplary embodiment, thedye injection system circuitry 212 may be configured to communicate withthe memory 204 and determine the weight of the garment corresponding tothe garment type. In various embodiments, the dye injection systemcircuitry 212 may be configured to determine, based on, for example, theweight of the garment, the appropriate magnitude factor to apply to therespective volumes of concentrated liquid dye configured to be dispensedat the ratio described above. For example, in various embodiments, thedye injection system circuitry 212 may retrieve data comprising one ormore lookup tables associated with a correlation of garment weight tototal volume of dyestuff required to fully dye the correspondinggarment(s). In various embodiments, the total volume of dyestuffrequired to fully dye the corresponding garment(s) may depend on aselected resultant garment color. As a non-limiting example, in variousembodiments, the total volume of dyestuff required to fully dye a firstgarment a proprietary resultant garment color of Dark Blue may begreater than the total volume of dyestuff required to fully dye a secondgarment of equal garment weight a proprietary resultant garment color ofLight Red. In such embodiments, regardless of the user-selectedresultant garment color, the total volume of dyestuff required to fullydye a garment of a known garment weight will not exceed the dyestuffabsorption capacity of a fully cationized garment of the correspondingweight.

As described herein, the dye injection system circuitry 212 may beconfigured to calibrate the total volume of concentrated liquid dyedispensed by the dye injection system based at least in part on thecationic concentration of the at least one garment. The total volume ofconcentrated liquid dye dispensed by the dye injection system may beoptimized so as to minimize the resultant volume of dyestuff remainingin the dyebath upon the execution of a dye cycle. For example, invarious embodiments, the total volume of concentrated liquid dyedispensed by the dye injection system may contain an amount of dyestuffthat is substantially less than or equal to the dyestuff absorptioncapacity of the garment. By way of non-liming example, various exemplarylook up tables corresponding to various proprietary resultant garmentcolors may include a total amount of dyestuff and/or total collectiveconcentrated liquid dye to be dispensed that is calibrated to, forexample, various garment weights, as follows:

Total Collective Proprietary Garment Concentrated Liquid Color WeightDye Volume Dark Blue 50 grams 9.00 mL 100 grams 18.00 mL 150 grams 27.00mL 200 grams 36.00 mL Light Red 50 grams 3.50 mL 100 grams 7.00 mL 150grams 10.50 mL 200 grams 14.00 mL

As a further non-liming example, various exemplary look up tablescorresponding to various proprietary resultant garment colors, such as,for example, Light Red, may include various volumes of respectiveconcentrated liquid dyes to be dispensed calibrated to, for example,various garment weights, as follows:

Volume of Concentrated Proprietary Garment Concentrated Liquid LiquidDye Color Weight Dye Components to Dispense Light Red 50 grams YellowOne 1.00 mL Orange One 0.50 mL Red Two 2.00 mL 100 grams Yellow One 2.00mL Orange One 1.00 mL Red Two 4.00 mL 150 grams Yellow One 3.00 mLOrange One 1.50 mL Red Two 6.00 mL 200 grams Yellow One 4.00 mL OrangeOne 2.00 mL Red Two 8.00 mL

In various embodiments, the dye injection system circuitry 212 may beconfigured to transmit the results of the calculations anddeterminations described above to the dye injection system 120. Invarious embodiments, the dye injection system circuitry 212 may beconfigured to transmit a dye injection completion signal to one or morecircuitry components of the controller 200. As a further non-limitingexample, the dye injection system circuitry 212 may be configured toreceive a garment pattern signal one or more components of thecontroller 200, wherein the dye injection system circuitry 212 may befurther configured to identify a garment cationic concentrationcorresponding to the received garment pattern signal.

As a non-limiting example, controller 200 (e.g., dye injection systemcircuitry 212) may receive data corresponding to a garment weight of 150grams and a user selection of a uniform proprietary Light Red resultantgarment color. As described herein, the dye injection system circuitry212 may retrieve data from a look up table noting that for 150 grams offully cationized cotton, in order to produce a resultant garment colorof Light Red, a dye injection system should dispense 3.0 mL of YellowOne concentrated liquid dye, 1.5 mL of Orange One concentrated liquiddye, and 6.0 mL of Red Two concentrated liquid dye into an exemplarydyeing machine. In various embodiments, the dye injection systemcircuitry 212 may be further configured to determine a dye injectionrate at which the three volumes of concentrated liquid dye may bedispensed based at least in part on the corresponding garment weight.

As a further non-limiting example, controller 200 (e.g., dye injectionsystem circuitry 212) may receive data corresponding to two size largecotton t-shirts and a user selection of a uniform proprietary Light Redresultant garment color. As described herein, the dye injection systemcircuitry 212 may retrieve data from a look up table noting that a sizelarge cotton t-shirt comprises a garment weight of 75 grams, and mayfurther determine that the garment weight of the one or more garments tobe dyed is 150 grams. As further described herein, the dye injectionsystem circuitry 212 may retrieve data from a look up table noting thatfor 150 grams of fully cationized cotton, in order to produce aresultant garment color of Light Red, the ratio of Yellow One dye toOrange One dye to Red Two dye should be 2:1:4. The dye injection systemcircuitry 212 may retrieve data from a look up table noting that thatfor 150 grams of fully cationized cotton, 10.50 mL of concentratedliquid dye may be dispensed to produce a resultant garment color ofLight Red. Based at least in part on the known percentage allocation ofthe various concentrated liquid dyes and the total collective volume ofconcentrated liquid dye to be dispensed, the dye injection systemcircuitry 212 may determine that 3.0 mL of Yellow One concentratedliquid dye, 1.5 mL of Orange One concentrated liquid dye, and 6.0 mL ofRed Two concentrated liquid dye should be dispensed into a dyeingmachine in order to produce two size large cotton t shirts having aLight Red resultant garment color.

As an alternative non-limiting example, controller 200 (e.g., dyeinjection system circuitry 212) may receive data corresponding to agarment weight of 150 grams and a user selection of a uniform custom redresultant garment color. In various embodiments, the dye injectionsystem circuitry 212 may determine, based at least in part on dataretrieved data from a look up table corresponding to a proprietary LightRed resultant garment color that is determined to be at leastsubstantially similar to the selected custom red color, that in order toproduce the custom red resultant garment color selected by the user,Yellow One concentrated liquid dye, Orange One concentrated liquid dye,and Red Two concentrated liquid dye should be dispensed at a ratio of1:1:2. The dye injection system circuitry 212 may further determine,based at least in part on retrieved data from a look up tablecorresponding to a proprietary Light Red resultant garment color and adetermined depth of shade of the custom red color, that that for 150grams of fully cationized cotton, 12 mL of concentrated liquid dye maybe dispensed in order to produce a resultant garment color of theuser-selected custom red. Based at least in part on the determinedpercentage allocation of the various concentrated liquid dyes and thetotal collective volume of concentrated liquid dye to be dispensed, thedye injection system circuitry 212 may determine that 3.0 mL of YellowOne concentrated liquid dye, 3.0 mL of Orange One concentrated liquiddye, and 6.0 mL of Red Two concentrated liquid dye should be dispensedinto the dyeing machine in order to produce a garments(s) having orangeoutput color at a full depth of shade.

In various embodiments, the power circuitry 214 may be configured toreceive power and power the controller 200. As non-limiting examples,the power circuitry 214 may comprise one or more batteries, one or morecapacitors, one or more constant power supplies (e.g., a wall-outlet),and/or the like. In some embodiments, the power circuitry 214 maycomprise an external power supply positioned outside of the apparatushousing 101 and configured to deliver alternating or direct currentpower to the controller 200. Further, in some embodiments, the powercircuitry 214 may comprise an internal power supply, for example, one ormore batteries, positioned within the apparatus housing 110.

The user interface circuitry 216 includes hardware components designedor configured to receive, process, generate, and transmit data, such asuser interface data. In various embodiments, the user interfacecircuitry 216 may be configured to generate user interface dataindicative of available resultant garment colors, a user-selected color,available garment types, a user-selected garment type, a user-selectedgarment weight, a dye cycle commencement signal, remaining dye cycletime, a dye cycle completion signal, and combinations thereof. In someembodiments, the user interface data may comprise a visual illustrationpreviewing a user-selected garment type in a user-selected color. Insome instances, the user interface data may comprise a list (e.g., aselectable drop-down list, an ordered grouping of selectable icons(e.g., clickable icons configured to be clicked by a mouse; virtualicons configured to be displayed on a touchscreen and pressed by auser's finger), a text-based prompt, a voice-based prompt) of availableresultant garment colors, garment weights, and/or garment types. Forinstance, the user interface circuitry 216 may include hardwarecomponents designed or configured to generate the user interface databased on any embodiment or combination of embodiments described withreference to FIGS. 1-3 .

In some embodiments, the user interface circuitry 216 may be incommunication with a display device (e.g., input-output circuitry 206, auser device, or a display device communicatively coupled thereto) andthus configured to transmit the user interface data to the displaydevice. For example, the user interface circuitry 216 may be configuredto generate user interface data and transmit the generated userinterface data to the input-output circuitry 206, and the input-outputcircuitry 206 may be configured to receive the user interface data anddisplay the received user interface data on one or more display screens.In various embodiments, for example, the user interface circuitry may beconfigured to receive user input (e.g., a user selection) at a displaydevice (e.g., a display screen) arranged proximate to and/or at a dyeingmachine 110.

In some embodiments, each of the dying machine circuitry 210, dyeinjection circuitry 212, and user interface circuitry 216 may include aseparate processor, specially configured field programmable gate array(FPGA), application specific interface circuit (ASIC), or cloud utilityto perform the above functions. In some embodiments, the hardwarecomponents described above with reference to the dying machine circuitry210, dye injection circuitry 212, and user interface circuitry 216 may,for instance, utilize communications circuitry 208 or any suitable wiredor wireless communications path to communicate with a user device, eachother, or any other suitable circuitry or device.

In some embodiments, one or more of the dying machine circuitry 210, dyeinjection circuitry 212, and user interface circuitry 216 may be hostedlocally by the controller 200. In some embodiments, one or more of thedying machine circuitry 210, dye injection circuitry 212, and userinterface circuitry 216 may be hosted remotely (e.g., by one or morecloud servers) and thus need not physically reside on the controller200. Thus, some or all of the functionality described herein may beprovided by a remote circuitry. For example, the controller 200 mayaccess one or more remote circuitries via any sort of networkedconnection that facilitates transmission of data and electronicinformation between the controller 200 and the remote circuitries. Inturn, the controller 200 may be in remote communication with one or moreof the dying machine circuitry 210, dye injection circuitry 212, anduser interface circuitry 216.

As described above and as will be appreciated based on this disclosure,embodiments of the present disclosure may be configured as systems,apparatuses, methods, mobile devices, backend network devices, computerprogram products, other suitable devices, and combinations thereof.Accordingly, embodiments may comprise various means including entirelyof hardware or any combination of software with hardware. Furthermore,embodiments may take the form of a computer program product on at leastone non-transitory computer-readable storage medium havingcomputer-readable program instructions (e.g., computer software)embodied in the storage medium. Any suitable computer-readable storagemedium may be utilized including non-transitory hard disks, CD-ROMs,flash memory, optical storage devices, or magnetic storage devices. Aswill be appreciated, any computer program instructions and/or other typeof code described herein may be loaded onto a computer, processor orother programmable apparatus's circuitry to produce a machine, such thatthe computer, processor, or other programmable circuitry that executesthe code on the machine creates the means for implementing variousfunctions, including those described herein.

In some embodiments, the user device may be embodied by one or morecomputing devices or systems that also may include processing circuitry,memory, input-output circuitry, and communications circuitry. Forexample, a user device may be a laptop computer on which an app (e.g., aGUI application) is running or otherwise being executed by processingcircuitry. In yet another example, a user device may be a smartphone onwhich an app (e.g., a webpage browsing app) is running or otherwisebeing executed by processing circuitry. As it relates to operationsdescribed in the present disclosure, the functioning of these devicesmay utilize components similar to the similarly named componentsdescribed above with respect to FIG. 2 . Additional description of themechanics of these components is omitted for the sake of brevity. Thesedevice elements, operating together, provide the respective computingsystems with the functionality necessary to facilitate the communicationof data with the example dyeing apparatus described herein.

In various applications, an exemplary method as disclosed herein may beimplemented in, for example, either a retail or manufacturing setting.

Method of Dyeing

FIG. 3 illustrates a flow diagram of an example method 300 in accordancewith various embodiments discussed herein.

At block 301, an exemplary method of dyeing a garment may comprisecationizing a garment such as, for example, a garment comprised ofcotton. As may be generally understood, cationizing a cotton garment maycomprise chemically modifying cellulosic macromolecules in order tointroduce a positive charge within the garment. Specifically,cationization may comprise the introduction of amino compounds into thegarment, the reaction of which may render the cellulose fibers presentwithin the garment cationic. Cationization creates an electrostaticinteraction between the positive charges on the cotton fiber and thenegative charges on the anionic dye, effectively increasing the cotton'saffinity for the anionic dye. In various implementations, this processmay increase the amount of dye exhausted by the cotton garment duringthe dyeing process. Further, cationization as described herein maygreatly reduce the need for large quantities of the additivestraditionally used to enhance the percentage of dye uptake, such as, forexample, various salts or other alkaline components, in the dyeingprocess. Cationization of a garment may be executed using a cationictreatment agent.

According to various embodiments, an entire garment may be cationized byapplying a volume of cationic treatment agent to the entire garment.Further, particular garment areas defining less than an entire garmentmay be cationized by selectively applying a volume of cationic treatmentagent to the particular garment area. As described herein, any givenvolume of cationic treatment agent contains an electronic charge. Thecollective electric charge of a particular volume of cationic treatmentagent may be proportional to the amount of cationic treatment agentwithin the particular volume (i.e., volume size). As described herein,prior to reaching its threshold of dyestuff absorption (i.e., saturationpoint), a cationized garment area will continue to absorb dyestuff froma dyebath either until all of the dyestuff has been exhausted from thedyebath, or for as long as the garment area maintains an electricalcharge. Thus, in various embodiments, the higher the cationicconcentration of a particular portion of a garment, the more dyestuffthat particular portion of the garment will retain (thereby increasingthe depth of shade of that particular portion of the garment).Accordingly, the concentration of cationic treatment agent applied to agarment may be selectively varied to affect the depth of shade of thegarment.

According to various embodiments, cationic treatment agent may beselectively applied to a garment using various application apparatusesand methods, such as, for example, screen printing, manual spraying(e.g., hand spraying), automated spraying (e.g., inkjet printing),and/or the like. In various embodiments, the cationic treatment maycomprise 3-chloro-2-hydroxypropyltrimethylammonium chloride (CHPTAC). Asjust one example, the cationic treatment agent may comprise Dow ECOFAST™Pure Sustainable Textile Treatment.

At block 302, an exemplary method of dyeing a garment may comprisemixing a volume of dyestuff with a volume of solvent to form aconcentrated liquid dye. In various embodiments, the concentrated liquiddye may comprise a mixture of a volume of dyestuff and a volume ofwater. The volume of water may be sufficiently mixed with the dyestuffsuch that the dyestuff is maintained in a state of suspension so as tofacilitate dispensing of the dyestuff into the dyeing machine as aconcentrated liquid dye. In various embodiments, the concentrated liquiddye may comprise a water to dyestuff ratio of between 2:1 and 50:1(e.g., 3:1 to 8:1). In various embodiments, an additive such as, forexample, a gel may be added to the liquid concentrated dye to furtherfacilitate a state of suspension. In various embodiments, a preservativeagent, such as, for example, Sodium Tripolyphosphate and/or anantimicrobial agent may be added to the liquid concentrated dye toexpand the useful lifespan of the concentrated liquid dye. It should beunderstood that any additive (e.g., a preservative agent) introducedinto the concentrated liquid dye will not affect the percentage of dyeuptake in the dyeing process.

In various embodiments, the mixing of a volume of dyestuff and a volumeof solvent to create a concentrated liquid dye may be repeated with oneor more volumes of dyestuff, each associated with a distinct color. Theresulting concentrated liquid dyes may each be associated with adistinct color correlating to the color of their respective volume ofdyestuff. As described herein, a dyeing process wherein the one or moreexemplary concentrated liquid dyes are at least substantially free ofvarious additives such as, for example, various added salt content(e.g., Sodium Chloride, Sodium Sulphate), alkaline content (e.g., SodiumHydroxide, Sodium Carbonate), dedusting agents, or other contaminants,should be understood to minimize the number of variables that may affecta resultant garment color. As such, such exemplary liquid concentrateddyes—consisting of dyestuff and water—enable a more predictable dyeingprocess capable of reliably and repeatedly producing a desired resultantgarment color. For example, each concentrated liquid dye may comprise aknown dyestuff concentration (i.e., the ratio of dyestuff to waterwithin the concentrated liquid dye). Using the known dyestuffconcentrations and a user-selected resultant garment color input, avolume of the one or more exemplary concentrated liquid dyes may betuned to achieve an absorption percentage of at least substantially 100%of a volume of dyestuff contained therein based solely on a proportionalrelationship of the volume of dyestuff to the weight of the garmentbeing dyed. The increased predictability that accompanies eliminatinginput variables such as the amount of water, the amount of dyeadditives, and the chemistry respectively associated therewith, reducesthe need for color trials (e.g., lab-dips) and color approvals, therebyenabling a dyeing process wherein fewer base concentrated liquid dyesare needed to produce a large number of available resultant garmentcolors.

In various embodiments, the one or more concentrated liquid dyes maydefine an array of between 1 and 20 (e.g., between 7 and 15) base colors(e.g., concentrated liquid dye colors) that may be selectively combinedin various proportions, thus enabling a large number of availableresultant garment colors. In one exemplary embodiment, a commercial dyeinjection system, as described herein, may be configured to produce upto 3 million dye input colors using between 7 and 15 base colors, theresultant dye input color being a color defined by a shade gamut withinthe realm of a given color space. For example, the between 7 and 15 basecolors, used in combination, may be configured to facilitate theproduction a resultant garment color, the resultant garment color beingone of up to 3 million colors defined by the shade gamut within therealm of the given color space.

In various embodiments, the one or more concentrated liquid dyes may berespectively stored in cartridges. The concentrated liquid dyecartridges may be disposed within a dye housing. In various embodiments,each of the one or more the concentrated liquid dye cartridges may beconfigured to be fluidly connected to a respective dispense header suchthat various proportions of the concentrated liquid dye may be injectedthrough a dispense header into a dyeing machine, mixing tank, ordelivery conduit.

At block 303, an exemplary method of dyeing a garment may comprise usinga dye injection system to determine by a processor a ratio of one ormore volumes of concentrated liquid dye to be injected into a dyeingmachine in order to produce a garment of a selected resultant color. Invarious embodiments, a garment parameter (e.g., a garment weight; agarment size, a garment SKU) and a resultant garment color may beselected by a user, for example, via a user interface. Accordingly, inorder to produce the resultant garment color selected by the user, aprocessor may determine the extent to which each of the concentratedliquid dyes will be dispensed into the dyeing machine for engagementwith the garment. In various embodiments, such an exemplary processordetermination may comprise two components: the percentage allocation ofthe respective concentrated liquid dye colors dispensed into the dyeingmachine and the volume of the total collective concentrated liquid dyeto be dispensed.

In various embodiments, each of the concentrated liquid dyes may berespectively associated with a concentrated liquid dye color. One ormore concentrated liquid dyes may be dispensed at various ratios suchthat the total collective concentrated liquid dye dispensed into thedyeing machine may comprise a dye input color configured to produce aresultant garment color pre-selected by a user. In various embodiments,the percentage allocation of the respective concentrated liquid dyecolors defines the dye input color and affects the shade of theresultant garment color.

Further, in various embodiments, the volume of each of the respectiveconcentrated liquid dyes dispensed (i.e., the amount of the totalcollective concentrated liquid dye) may be based at least in part on agarment parameter corresponding to the at least one garment in thedyeing machine. In various embodiments, a garment parameter may be acharacteristic of a garment and/or (e.g., collective group of garments)that defines, at least in part, the capacity of the garment forabsorbing a volume of dyestuff (e.g., the dyestuff absorption capacityof a garment). As non-limiting examples, a garment parameter may be agarment weight and/or a cationic concentration of a garment. Forexample, in various embodiments, the volume of each of the respectiveconcentrated liquid dyes dispensed (i.e., the amount of the totalcollective concentrated liquid dye) corresponds to the weight of thegarment in the dyeing machine. In various embodiments, a maximum volumeof concentrated liquid dye able to be absorbed by a garment may be knownto produce a resultant garment color of full depth; that maximum volumedefines the maximum volume of concentrated liquid dye that may bedispensed into the system for the garment. In such an exemplarycircumstance, the total dispensed volume of concentrated liquid dye thatcontains an amount of dyestuff is an amount of dyestuff substantiallyless than or equal to the dyestuff absorption capacity of the garment.In various embodiments, a lesser amount of dye may be injected into themachine in order to affect the depth of the shade of dye input color(i.e., produce, for example, a lighter shade of the dye input color).Accordingly, in various embodiments, the resultant garment color may bea function of both the percentage allocation of the respectiveconcentrated liquid dye colors and the amount of total collectiveconcentrated liquid dye dispensed into the system. Accordingly, invarious embodiments, the processor may determine the proportion of eachof the concentrated liquid dyes to the total collective concentratedliquid dye dispensed based on the user-selected resultant garment color.Similarly, in various embodiments, the total collective volume ofconcentrated liquid dye dispensed into the system may vary based atleast in part on the user-selected resultant garment color.

Further, in various embodiments, given a selected resultant garmentcolor, the volume of the total collective concentrated liquid dyeinjected into the dyeing machine—and thus the volume of the individualconcentrated liquid dyes injected into the dyeing machine—may bedetermined solely by the weight of the garment to be dyed. Accordingly,in various embodiments, the processor may determine the volume of thetotal collective concentrated liquid dye dispensed based on theuser-selected garment weight. In such an exemplary method, a processormay determine the volume of each of the concentrated liquid dyes presentwithin the dye injection system to be dispensed based on theuser-selected garment weight and desired resultant garment color. Forexample, the processor may be configured to determine, based at least inpart on the user-selected garment weight and desired resultant garmentcolor, the ratio of various dyestuffs that corresponds to the desiredresultant garment color and the total amount of dyestuff required toproduce the resultant garment color at a full depth of shade. Based atleast in part on the known dyestuff concentrations of each of theconcentrated liquid dyes, the processor may determine the volume of eachof the concentrated liquid dyes to be dispensed such that the calculatedamount of dyestuff respectively contained therein, as described above,is dispensed into the dyeing machine.

At block 304, an exemplary method of dyeing a garment may compriseinjecting the volume of the one or more concentrated liquid dyesdetermined by the processor from the dye injection system into thedyeing machine. In various embodiments, the dyeing machine may be atleast partially filled with an at least substantially clean solvent.Each volume of concentrated liquid dye may be dispensed from arespective dye cartridge, through a corresponding dispense header, anddirectly into a dyeing machine. In various embodiments, a garment may bepresent in the dyeing machine prior to the one or more volumes ofconcentrated liquid dye being injected.

In various embodiments, the dyeing machine may be, for example, a dyeingvessel, and may be configured to be fluidly connected to one or moreholding tanks such that a volume of solvent stored in the one or moreholding tanks may be dispensed into the dyeing machine. The concentratedliquid dye and the solvent dispensed into the dyeing machine may definea dyebath. In an exemplary embodiment, the solvent may be, for example,water. Due to the pre-cationization of the garment—which leads tomaximized dye exhaustion and the elimination of the need to add salts tothe dye—the amount of solvent dispensed into the dyeing machine is not acritical variable to be considered in the exemplary method as disclosedherein. While the amount of solvent dispensed into the dyeing machinemay vary based on the volumetric capacity of the dyeing machine, theratio of concentrated liquid dye to solvent present in the dyebath hasno effect on the efficacy of the method disclosed herein.

As noted above, in various embodiments, the one or more volumes ofconcentrated liquid dye may be dispensed directly into the dyeingmachine, may be dispensed into a mixing tank, or may be dispensed into acommon delivery conduit.

At block 305, an exemplary method of dyeing a garment may compriseoperating the dyeing machine until at least substantially all of thevolume of dyestuff present within the one or more concentrated liquiddyes dispensed into the dyeing machine has been absorbed by the garment.The dyeing machine may be configured to encourage interaction betweenthe garment and the dyebath. Further, the dyeing machine may beconfigured to begin operation after the one or more volumes ofconcentrated liquid dye have been dispensed into the dyeing machine fromthe dye injection system. In various embodiments, operating the dyeingmachine may comprise executing a dyeing cycle.

In various embodiments, the runtime of a dye cycle may be proportionalto at least the weight of the garment in the dyeing machine, the depthof the shade of the resultant garment color, and the exhaustion of thedyestuff in the fabric of the garment. In an exemplary implementation, adye cycle may comprise a length of time of between 20 and 60 minutes(e.g., between 30 and 45 minutes). Further, in various embodiments, thedyeing machine may be configured maintain the dyebath at a substantiallyambient temperature. For example, the dyeing machine may be configuredmaintain a dyebath temperature of between 10 and 75 degrees Celsius(e.g., between 18 and 40 degrees Celsius) throughout a dye cycle. Suchan exemplary method as described herein, may eliminate the need to heatthe dyebath to temperatures substantially higher than ambienttemperature (e.g., 60 degrees Celsius), thereby drastically reducing theamount of energy consumed during the dyeing process in comparison totraditional dyeing methods.

In various embodiments, the entirety of the volume of dyestuff presentin the dyebath at the beginning of the dye cycle may be absorbed by thegarment during the dye cycle. In various embodiments, the resultantdyebath may be comprised exclusively of water; there may be no remainingvolume of dyestuff, salt, or other forms of effluent present in thedyebath. Alternatively, in various embodiments, there might be asubstantially small volume of dyestuff and/or one or more componentscontained within the concentrated liquid dye remaining in the dyebath atthe end of a dyeing cycle. For example, in various embodiments, theresultant dyebath may be free of additives conventionally used toenhance the percentage of dye uptake in the dyeing process as a resultof dispensing a calibrated volume of concentrated liquid dye, asdescribed herein. In various embodiments, the garment may besubsequently washed and/or dried after the dye cycle has concluded. Thegarment may be subsequently washed and/or dried using either the dyeingmachine or any other suitable machine configured to wash and/or dry thegarment as described herein.

At block 306 an exemplary method of dyeing a garment may comprisefiltering the dyebath so as to remove the entirety of a residual volumeof dyestuff. In various embodiments, after a dyeing cycle has ended, thedyebath may be filtered such that any volume of dyestuff remaining inthe dyebath may be removed, effectively leaving a substantially cleanwater that may be suitable for reuse in the dyeing process. In variousembodiments, filtering the dyebath may comprise exposing the dyebath toa filtration system. For example, filtering the dyebath may compriseloading a dyeing machine or other vessel to which the dyebath has beentransferred (e.g., a filtration system reservoir) with a supplementalmaterial that has been treated to absorb the entirety of residual volumeof dyestuff. In various embodiments, the supplemental material may becationized, and may comprise excess fabric, fiber, yarn, cotton, orother garment portions. In various embodiments, the supplementalmaterial may, for example, be sewn into a polypropylene container (i.e.,a “tea-bag”) which may be placed into the dyebath such that the entiretyof the residual volume of dyestuff present in the dyebath may beabsorbed by the supplemental fabric. Alternatively, in variousembodiments, the filtration system may comprise a vessel with one ormore strainers configured to remove the entirety of the residual volumeof dyestuff from the dyebath.

At block 307 an exemplary method of dyeing a garment may compriserecirculating the volume of at least substantially clean solvent forreuse in a subsequent dye cycle. In various embodiments, the volume ofat least substantially clean solvent may comprise a volume of cleanwater. In various exemplary embodiments, the volume of water may betransferred directly from either the dyeing machine or the filtrationsystem to one or more holding tanks for storage. The holding tanks, forexample, may comprise a plurality of reservoirs in fluid communicationwith the dyeing machine and/or the filtration system. The holding tanksmay be configured to receive a volume of at least substantially cleansolvent from either the dyeing machine and/or the filtration system andmay be configured to send a volume of solvent back to the dyeing machinebefore a new dye cycle begins. Alternatively, in various embodiments,the volume of water may be transferred directly from the filtrationsystem back into the dyeing machine for reuse with the subsequent dyecycle. As described herein, an exemplary method comprises asubstantially closed-loop system with respect to the solvent.

In various applications, an exemplary method as disclosed herein may beimplemented in, for example, either a retail or manufacturing setting.

It is to be understood that the present invention is not limited to theembodiments described above and illustrated in the drawings; rather, theskilled person will recognize that many changes and modifications may bemade within the scope of the disclosed invention. For example, it shouldbe understood that while the exemplary embodiments described above aredirected to dyeing a garment, the method and apparatus embodimentsdisclosed herein may be configured to dye a weight (or mass) of materialother than a garment, such as, for example, garment thread, yarn, wovensheets, any colorable fabric, or any other dye absorbent material.

Dyestuff and Concentrated Liquid Dye Composition

In various embodiments, the method and apparatus for dyeing garmentsdisclosed herein may utilize a volume of dyestuff to color a garment.Dyestuff, as described herein, may be a powder, for example, and maycomprise a composition of soluble substances that collectively may beassociated with a particular color. In various embodiments, a volume ofdyestuff may be mixed with water to create a concentrated liquid dye,which may be associated with the same color as the volume of dyestuffcontained therein. The volume of water may be sufficiently mixed withthe dyestuff for the purpose of facilitating the injection of thedyestuff into a dyeing machine. Upon being injected into the dyeingmachine, the concentrated liquid dye may interact with a volume ofsolvent present in the dyeing machine, thereby creating a dyebath. Asdescribed herein, a garment may be sufficiently submerged within thedyebath such that it may absorb at least substantially all of the volumeof dyestuff that—in the form of concentrated liquid dye—was injectedinto the dyebath.

In various embodiments, the dyestuff as described herein may be areactive dye. Further, in various embodiments, the dyestuff may be anydirect dye or acid dye suitable for use with the apparatus and methoddescribed herein.

The exemplary method and apparatus described above may, in variousembodiments, include using a dyestuff consisting exclusively ofchromophore. For example, an exemplary volume of dyestuff may notcontain additive dyeing enhancement agents such as, for example, cuttingagents (e.g., potato starch), added salt content, water-emulsifiablededusting oils, and/or the like.

Accordingly, the concentrated liquid dye used in various embodiments mayconsist only of water and chromophore. Critically, the exemplary methodsand apparatuses disclosed herein may be configured to utilize aconcentrated liquid dye that does not contain many of the additivesconventionally used to enhance the percentage of dye uptake in thedyeing process, such as, for example, various added salt content (e.g.,Sodium Chloride, Sodium Sulphate), alkaline content (e.g., SodiumHydroxide, Sodium Carbonate), or other contaminant. In variousembodiments, an exemplary volume of concentrated liquid may include oneor more preservatives configured to expand the useful lifespan of theconcentrated liquid dye, such as, for example, Sodium Tripolyphosphate,and/or an antimicrobial agent.

Further, it should be understood that in various embodiments, thedyestuff concentration within the concentrated liquid dye (i.e., theratio of dyestuff to water in the concentrated liquid dye) may havelittle to no effect on the efficacy of the dyeing process. In variousembodiments, the sole variable critical to the dyeing of the garment maybe the volume of dyestuff dispensed into the dyeing machine; theadditional solvent added to the dyestuff to facilitate injection, onceinjected, may simply become subsumed into the larger volume of solventalready present in the dyebath. While the volume of dyestuff in thedyebath may interact with the garment in the dyeing machine, the volumeof solvent present within the concentrated liquid dye may become apassive component of the dyebath.

Method of Dyeing a Patterned Garment

FIG. 4 illustrates a flow diagram of an example method 400 in accordancewith various embodiments discussed herein.

At block 401, an exemplary method of dyeing a patterned garment maycomprise receiving a garment pattern instruction corresponding to agarment pattern. In various embodiments, the garment pattern maycomprise one or more pattern elements, wherein each pattern elementcomprises a pattern element shape, pattern element color, and patternelement depth of shade. Garment pattern instructions may comprise adetailed description and/or one or more commands (e.g., computerinstructions) corresponding to various attributes of a garment pattern.In various embodiments, the garment pattern instructions may be providedvia user input from a user in either a retail or manufacturing setting.

Each of the one or more pattern elements may be defined by a pluralityof pattern element characteristics, such as, for example, patternelement shape, pattern element color, and pattern element depth ofshade. As described herein, pattern element shape may be defined by boththe configuration of the outer boundary of a pattern element, as well asthe location of the pattern element on the garment. Pattern elementcolor may be defined as the output color of a garment at a particularpattern element. Further, the pattern element depth of shade may bedefined as a relative lightness of a pattern element color. For example,a pattern element depth of shade of full depth, or 100%, may define thepattern element color as selected by a user, while pattern elements withdecreasing depths of shade will appear increasingly fainter (i.e.,lighter, assuming a garment of a white base color). In variousembodiments, depth of shade at a particular garment area may be affectedby three depth of shade input variables: the volume of dyestuff (i.e.,concentrated liquid dye) used in a dye cycle, the dye cycle runtime, andthe concentration of cationic treatment agent applied at the garmentarea (“cationic concentration”). Accordingly, as described herein, oneor more of the aforementioned depth of shade input variables may beselectively varied, alone or in combination, to achieve a desiredpattern element depth of shade.

At block 402, an exemplary method of dyeing a patterned garment maycomprise applying a volume of cationic treatment agent at one or morelocalized garment areas of a garment corresponding to each of the one ormore pattern element shapes. In various embodiments, a volume ofcationic treatment agent may be applied to a garment as part of acationization process. As may be generally understood, cationization maycomprise a pretreatment process wherein the cellulosic macromolecules ofa cotton garment may be chemically modified in order to introduce apositive charge within at least a portion of the garment. Cationizationcreates an electrostatic interaction between the positive charges on thecotton fiber and the negative charges on the anionic dye, effectivelyincreasing the cotton's affinity for the anionic dye. A garment may becationized by applying a cationic treatment agent to the garment.

As described herein, particular garment areas defining less than anentire garment may be cationized by selectively applying a volume ofcationic treatment agent to the particular garment area. A volume ofcationic treatment agent may be applied to one or more garment areascorresponding to the respective pattern element shapes of each of theone or more pattern elements. For example, the volume of cationictreatment agent may be applied so as to one or more garment areascomprising shapes, letters, numbers, or any combination thereof.Further, in various embodiments, the volume of cationic treatment agentmay be applied across a garment area in either progressively increasingor progressively decreasing cationic concentration such that when thegarment is dyed, as described herein, at least part of the garmentpattern exhibits a gradient effect rather than a discrete change incolor or depth of shade. As described herein, the gradient effect wouldbe the result of the progressive change in the pattern element depth ofshade corresponding to a gradient cationic concentration at that garmentarea. The cationic treatment agent may be applied in any state thatallows for the cationic treatment agent to penetrate the fibers of thegarment, such as, for example, a spray, a liquid, and/or or a gel.

In various embodiments, cationic treatment agent may be selectivelyapplied to a garment using various application apparatuses and methods,such as, for example, screen printing, manual spraying (e.g., handspraying), automated spraying (e.g., inkjet printing), and/or the like.In various embodiments, the cationic treatment agent may comprise3-chloro-2-hydroxypropyltrimethylammonium chloride (CHPTAC). As just oneexample, the cationic treatment agent may comprise Dow ECOFAST™ PureSustainable Textile Treatment.

As described herein, any given volume of cationic treatment agentcontains an electronic charge. The collective electric charge of aparticular volume of cationic treatment agent may be proportional to theamount of cationic treatment agent within the particular volume (i.e.,volume size). Accordingly, the smaller the garment area over which aparticular volume of cationic treatment agent is dispersed, the moreconcentrated the volume of cationic treatment agent will be, and thehigher the electrical charge of the garment will be over that garmentarea. As described herein, prior to reaching its threshold of dyestuffabsorption (i.e., saturation point), a cationized garment area willcontinue to absorb dyestuff from a dyebath either until all of thedyestuff has been exhausted from the dyebath, or for as long as thegarment area maintains an electrical charge. Thus, in variousembodiments, the higher the cationic concentration of a particularcationized garment area, the more dyestuff the particular garment areawill retain, thereby increasing the depth of shade at that particularcationized garment area. Accordingly, a concentration of cationictreatment agent applied to a pattern element may be selectively variedto affect the depth of shade of a pattern element.

At block 403, an exemplary method of dyeing a patterned garment maycomprise curing the volume of cationic treatment agent at each of theone or more pattern elements. As is generally known, a garment may becured upon cationization in order to solidify the settlement of a volumeof cationic treat in a particular location on a garment, so as to avoidmigration or runoff. In various embodiments, curing at least a portionof a garment may comprise one or more known curing processes, such aspad-dry curing, pad-flash curing, drip dry curing, and/or the like.

At block 404, an exemplary method of dyeing a patterned garment maycomprise dyeing a garment until at least substantially all of a volumeof cationic treatment agent applied to the garment has been neutralizedby an exhausted volume of dyestuff, wherein the dyeing machine isconfigured to encourage interaction between the garment and a dyebath.In various embodiments, a dyeing machine, as described herein, may beconfigured to execute at least a portion of the dyeing operation. Insuch circumstances, the dyeing machine encourages interaction betweenthe garment and the dyebath. The dyestuff utilized in the dyeingoperation may correspond to the garment pattern output color and/or thepattern element color of the one or more pattern elements, as selectedby the user. In various embodiments, operating the dyeing machine maycomprise executing a dyeing cycle.

In various embodiments, as described herein, a concentrated liquid dyeutilized during the dyeing operation may be void of any salts or otheralkali materials such that the concentrated neutral charge may itselfcomprise an electrical charge. Further, due at least in part to thecationization process as described herein, the dye cycle may be executedat a substantially ambient temperature, which may be known to negativelyaffect the uptake of dyestuff by an untreated garment. As such, at leastsubstantially all of a volume of dyestuff absorbed by a garment may beabsorbed by the one or more pattern elements of the garment to which thecationic treatment agent was applied. The cationized garment areasdefined by the one or more pattern element shapes may continue to absorbdyestuff until their respective electric charge has been neutralized.Accordingly, a neutral garment area without an electric charge, such as,for example, an untreated (i.e., non-cationized) garment area or agarment area that has absorbed a volume of dyestuff such that it hasbecome neutralized, may absorb a relatively insignificant amount ofdyestuff (i.e., little to no dyestuff) in comparison to the one or morecationized pattern elements of the garment. Untreated garment areas mayat least substantially maintain the original color of the un-dyedgarment throughout the dyeing operation. Upon neutralization of each ofthe one or more pattern areas, the one or more pattern elements of thegarment pattern may each exhibit a pattern element color correspondingto the color of the volume of dyestuff used in the dyeing operation anda pattern element depth of shade that is at least substantiallyproportional to the respective cationic concentration of the patternelement, as described herein. The variance in color and depth of shadebetween untreated garment areas and the one or more pattern elements, aswell as the variance in depth of shade amongst the one or more patternelements, as described herein, creates an overall garment aestheticwhich may define the garment pattern.

In various embodiments, the runtime of a dye cycle may be proportionalto the weight of the garment in the dyeing machine, the desired depth ofthe shade of the resultant garment color, the volume of cationictreatment agent applied to the garment, and/or the exhaustion of thedyestuff in the fabric of the garment. In an exemplary implementation, adye cycle may comprise a length of time of between 20 and 60 minutes(e.g., between 30 and 45 minutes). Further, in various embodiments, thedyeing machine may be configured maintain the dyebath at a substantiallyambient temperature. For example, the dyeing machine may be configuredmaintain a dyebath temperature of between 10 and 75 degrees Celsius(e.g., between 18 and 40 degrees Celsius) throughout a dye cycle. Suchan exemplary method as described herein, may eliminate the need to heatthe dyebath to temperatures substantially higher than ambienttemperature (e.g., 60 degrees Celsius), thereby drastically reducing theamount of energy consumed during the dyeing process in comparison totraditional dyeing methods.

In various embodiments, the runtime of a dye cycle may be selectivelyshortened so as to affect the pattern element depth of shade of the oneor more pattern elements. As a non-limiting example, an exemplary dyecycle may comprise a length of time of approximately 35 minutes and mayutilize a volume of dyestuff sufficient to provide one or more patternelements with a full pattern element depth of shade to dye a garment.The 35-minute dye cycle runtime may define a length of time sufficientto allow the entirety of a volume of dyestuff present in a dyebath atthe beginning of the dye cycle to be absorbed by the one or more patternelements of the garment. In such a circumstance, the one or more patternelements may comprise a full pattern element depth of shade. Further, invarious embodiments, the runtime of a dye cycle may be selectivelyshortened such that the one or more pattern elements comprise a lesser(i.e., lighter) pattern element depth of shade. Using the samenon-limiting example described above, if the dye cycle were stoppedafter a 25-minute runtime, the one or more pattern elements wouldcomprise a pattern element depth of shade that is lighter than that ofthe one or more pattern elements exposed to a 35-minute runtime.Further, if the dye cycle were stopped after a 15-minute runtime, theone or more pattern elements would comprise a pattern element depth ofshade that is lighter than that of the one or more pattern elementsexposed to a 25-minute runtime. Accordingly, as described herein, theruntime of a dye cycle may be a depth of shade input variable that maybe calibrated to achieve a desired pattern element depth of shade.

As a further example, FIG. 10 shows six different garment portions thatwere each subjected to an experimental dyeing process, the six differentgarment portions being representative of six different garments and/orsix different pattern elements within the respective garments. Each ofthe garment portion was subjected to a substantially identical dyeprocess, wherein each of the garment portions comprised an identicalcationic concentration and an identical volume of dyestuff was injectedinto a dyeing machine for each of the respective dye cycles. However,the dye cycle runtime for each of the six experimental dye cycles wasvaried. The table below provides the respective dye cycle runtimesassociated with each of the six garment portions:

Garment Portion 1001 10 minutes Garment Portion 1002 5 minutes GarmentPortion 1003 3 minutes Garment Portion 1004 1 minutes Garment Portion1005 30 seconds Garment Portion 1006 15 seconds

As shown in FIG. 10 , garment portion 1001, which was exposed to thevolume of dyestuff for the greatest amount of time, comprises thefullest depth of shade when compared to the five other garment elements.Conversely, garment portion 1006, which was exposed to the volume ofdyestuff for the least amount of time, comprises the least full (i.e.,lightest) depth of shade when compared to the five other garmentelements. Further, each of the garment portions comprising anintermediate depth of shade 1002, 1003, 1004, 1005 exhibits a differentdepth of shade relatively corresponding to the runtime of its respectivedye cycle.

Returning to the description of the exemplary embodiment depicted inFIG. 4 , in various embodiments, the entirety of the volume of dyestuffpresent in the dyebath at the beginning of the dye cycle may be absorbedby the garment during the dye cycle. Accordingly, the volume of dyestuffutilized in the dyeing operation may be selectively reduced so as toaffect the pattern element depth of shade of the one or more patternelements. As a non-limiting example, an exemplary dyeing operation maycomprise using three liters of concentrated liquid dye to dye a garment.In such a circumstance, the entirety of the volume of dyestuff presentin a dyebath at the beginning of a dye cycle may be absorbed by the oneor more pattern elements of the garment. Further, the volume of dyestuffpresent within the three liters of concentrated liquid dye may providethe one or more pattern elements with a full pattern element depth ofshade. Further, in various embodiments, the volume of dyestuff utilizedin the dyeing operation may be selectively reduced such that the one ormore pattern elements comprise a lesser (i.e., lighter) pattern elementdepth of shade. Using the same non-limiting example described above, iftwo liters of concentrated liquid dye were utilized to dye the garment,the one or more pattern elements would comprise a pattern element depthof shade that is lighter than that of the one or more pattern elementsexposed to the volume of dyestuff present within the three liters ofconcentrated liquid dye. Further, if only one liter of concentratedliquid dye were utilized to dye the garment, the one or more patternelements would comprise a pattern element depth of shade that is lighterthan that of the one or more pattern elements exposed to the volume ofdyestuff present within the two liters of concentrated liquid dye.Accordingly, as described herein, the volume of dyestuff utilized in thedyeing operation may be a depth of shade input variable that may becalibrated to achieve a desired pattern element depth of shade.

As described herein, in an exemplary embodiment wherein the entirety ofthe volume of dyestuff present in the dyebath at the beginning of thedye cycle may be absorbed by the garment during the dye cycle, theresultant dyebath may be comprised exclusively of water; there may be noremaining volume of dyestuff, salt, or other forms of effluent presentin the dyebath. Alternatively, in various embodiments, there might be asubstantially small volume of dyestuff and/or one or more componentscontained within the concentrated liquid dye remaining in the dyebath atthe end of a dyeing cycle. For example, in various embodiments, theresultant dyebath may be free of additives conventionally used toenhance the percentage of dye uptake in the dyeing process as a resultof dispensing a calibrated volume of concentrated liquid dye, asdescribed herein. In various embodiments, the garment may besubsequently washed and/or dried after the dye cycle has concluded. Thegarment may be subsequently washed and/or dried using either the dyeingmachine or any other suitable machine configured to wash and/or dry thegarment as described herein.

It should be understood that in various embodiments, a method for dyeinga patterned garment may comprise, in part or in whole, a method fordyeing garments as described herein, and may utilize an apparatus fordyeing garments as described herein. Further, it should be understoodthat any dyeing technique, process, and/or apparatus operable inconjunction with one or more of the exemplary embodiments of the methodfor dyeing a patterned garment described herein may be utilized.

At block 405, an exemplary method of dyeing a patterned garment mayfurther comprise mixing one or more volumes of dyestuff with one or morevolumes of solvent to form one or more concentrated liquid dyes. Invarious embodiments, the concentrated liquid dye may comprise a mixtureof a volume of dyestuff and a volume of water. The volume of water maybe sufficiently mixed with the dyestuff such that the dyestuff ismaintained in a state of suspension so as to facilitate dispensing ofthe dyestuff into the dyeing machine as a concentrated liquid dye. Invarious embodiments, the concentrated liquid dye may comprise a water todyestuff ratio of between 2:1 and 50:1 (e.g., 3:1 to 8:1). In variousembodiments, an additive such as, for example, a gel may be added to theliquid concentrated dye to further facilitate a state of suspension; anyadditive introduced into the concentrated liquid dye will not affect thepercentage of dye uptake in the dyeing process.

In various embodiments, the mixing of a volume of dyestuff and a volumeof solvent to create a concentrated liquid dye may be repeated with oneor more volumes of dyestuff, each associated with a distinct color. Theresulting concentrated liquid dyes may each be associated with adistinct color correlating to the color of their respective volume ofdyestuff. In various embodiments, the one or more concentrated liquiddyes may define an array of between 1 and 20 colors (e.g., between 7 and12 colors) that may be selectively combined in various proportions, thusenabling a large number of available resultant pattern colors, asdescribed herein.

In various embodiments, the one or more concentrated liquid dyes may berespectively stored in cartridges. The concentrated liquid dyecartridges may be disposed within a dye housing. In various embodiments,each of the one or more the concentrated liquid dye cartridges may beconfigured to be fluidly connected to a respective dispense header suchthat various proportions of the concentrated liquid dye may be injectedthrough a dispense header into a dyeing machine, mixing tank, ordelivery conduit.

At block 406, an exemplary method of dyeing a patterned garment mayfurther comprise using a dye injection system to determine by aprocessor a volume of one or more concentrated liquid dyes to beinjected into a dyeing machine in order to produce a garment of aselected output color. In various embodiments, as described above, agarment weight and a pattern color may be selected by a user via a userinterface. Accordingly, in order to produce the resultant patternelement color selected by the user, a processor may determine the extentto which each of the concentrated liquid dyes will be dispensed into thedyeing machine for engagement with the garment. In various embodiments,such an exemplary processor determination may comprise two components:the percentage allocation of the respective concentrated liquid dyecolors dispensed into the dyeing machine and the volume of the totalcollective concentrated liquid dye to be dispensed.

In various embodiments, each of the concentrated liquid dyes may berespectively associated with a concentrated liquid dye color. One ormore concentrated liquid dyes may be dispensed at various ratios suchthat the total collective concentrated liquid dye dispensed into thedyeing machine may comprise a dye input color configured to produce aresultant garment color pre-selected by a user. In various embodiments,the percentage allocation of the respective concentrated liquid dyecolors defines the dye input color and affects the resultant garmentcolor.

Further, in various embodiments the volume of each of the respectiveconcentrated liquid dyes dispensed (i.e., the amount of the totalcollective concentrated liquid dye) may correspond to the weight of thegarment in the dyeing machine. In various embodiments, a maximum volumeof dyestuff able to be absorbed by a garment may be known to produce aresultant garment color of full depth; that maximum volume defines themaximum volume of concentrated liquid dye that may be dispensed into thesystem for the garment. In various embodiments, a lesser amount of dyemay be injected into the machine in order to affect the depth of theshade of dye input color (i.e., produce, for example, a lighter shade ofthe dye input color). Accordingly, in various embodiments, the resultantgarment color may be a function of both the percentage allocation of therespective concentrated liquid dye colors and the amount of concentratedliquid dye dispensed into the system. Accordingly, in variousembodiments, the processor may determine the proportion of each of theconcentrated liquid dyes to the total collective concentrated liquid dyedispensed based on the user-selected resultant garment color.

Further, in various embodiments, the volume of each of the respectiveconcentrated liquid dyes dispensed (i.e., the amount of the totalcollective concentrated liquid dye) may be further calibrated to accountfor the fact that the dyestuff may only be absorbed by garment areascorresponding to the one or more pattern element shapes of the one ormore pattern elements, which may define less than the entire garment. Insuch a circumstance, the amount of the total collective concentratedliquid dye may be proportionally reduced to correspond to the weight ofthe one or more garment areas corresponding to the one or more patternelements.

Further, in various embodiments, the volume of each of the respectiveconcentrated liquid dyes dispensed (i.e., the amount of the totalcollective concentrated liquid dye) may be further calibrated based onthe capacity of the one or more pattern elements to absorb dyestuff. Forexample, the amount of the total collective concentrated liquiddye—which should be understood to comprise a volume of dyestuff, asdescribed herein—may be calibrated to be dispensed in proportion to thedyestuff absorption capacity of a garment, defined, at least in part, bythe volume of cationic treatment agent applied to the garment. In such acircumstance, the amount of the total collective concentrated liquid dyemay be reduced to accommodate a cationic concentration of one or more ofthe one or more pattern elements that is less than full capacity (i.e.,a cationic concentration that chemically creates an absorption thresholdthat is lower than a garment area is physically capable of absorbing).

In various embodiments, given a selected resultant garment color, thevolume of the total collected concentrated liquid dye injected into thedyeing machine—and thus the volume of the individual concentrated liquiddyes injected into the dyeing machine—may be determined solely by theweight of the garment to be dyed. Accordingly, in various embodiments,the processor may determine the volume of the total collectiveconcentrated liquid dye dispensed based on the user-selected garmentweight. In such an exemplary method, a processor may determine thevolume of each of the concentrated liquid dyes present within the dyeinjection system to be dispensed based on the user-selected garmentweight and resultant garment color.

At block 407, an exemplary method of dyeing a patterned garment mayfurther comprise injecting the volume of one or more concentrated liquiddyes determined by the processor into a dyeing machine, wherein thedyeing machine is loaded with the garment and is at least partiallyfilled with an at least substantially clean solvent. Each volume ofconcentrated liquid dye may be dispensed from a respective dyecartridge, through a corresponding dispense header, and directly into adyeing machine. In various embodiments, a garment may be present in thedyeing machine prior to the one or more volumes of concentrated liquiddye being injected.

In various embodiments, a dyeing machine may be, for example, a dyeingvessel, and may be configured to be fluidly connected to one or moreholding tanks such that a volume of solvent stored in the one or moreholding tanks may be dispensed into the dyeing machine. The concentratedliquid dye and the solvent dispensed into the dyeing machine may definea dyebath. In an exemplary embodiment, the solvent may be, for example,water. In various embodiments, due to the pre-cationization of thegarment—which leads to maximized dye exhaustion and the elimination ofthe need to add salts to the dye—the amount of solvent dispensed intothe dyeing machine is not a critical variable to be considered in theexemplary method as disclosed herein. While the amount of solventdispensed into the dyeing machine may vary based on the volumetriccapacity of the dyeing machine, the ratio of concentrated liquid dyeand/or dyestuff to solvent present in the dyebath has no effect on theefficacy of the method disclosed herein.

As noted above, in various embodiments, the one or more volumes ofconcentrated liquid dye may be dispensed directly into the dyeingmachine, may be dispensed into a mixing tank, or may be dispensed into acommon delivery conduit.

At block 408, an exemplary method of dyeing a patterned garment mayfurther comprise calibrating a volume of one or more concentrated liquiddyes injected into a dyeing machine so as to determine a minimum volumeof concentrated liquid dye required to neutralize substantially all ofthe volume of cationic treatment applied to a particular garment design(e.g., a garment with one or more pattern elements each comprising apattern element depth of shade corresponding to a cationicconcentration). In various embodiments, calibrating the volume ofconcentrated liquid dye injected into a dyeing machine for such agarment may comprise completing a first dyeing operation, dispensing theresultant dyebath containing the resultant volume of dyestuff, andrepeating the dyeing operation with a different volume of concentratedliquid dye (e.g., with a lesser volume of injected concentrated liquiddye if the resultant dyebath in the first operation contains excessdyestuff, or with a greater volume of injected concentrated liquid dyeif the resultant dyebath in the first operation does not contain excessdyestuff). The calibration process may comprise an empiricalmodification of the volume of concentrated liquid dye that isiteratively repeated until a volume of concentrated liquid dye isinjected into a dyeing machine wherein at least substantially all of theinjected volume of dyestuff neutralizes at least substantially all ofthe volume of cationic treatment agent applied to the garment.

As will be appreciated from the description herein, this calibrationprocess assists in efficiently dyeing garments with complex patternelements. As a result of calibration, the resultant dyebath consists ofa substantially clean volume of solvent suitable for reuse. In variousembodiments in which reproduction of a patterned garment of a particularweight and a particular garment pattern may be desirable, calibratingthe volume of concentrated liquid dye injected into a dyeing machine mayincrease the efficiency of the dyeing process.

Upon dyeing a garment until at least substantially all of a volume ofcationic treatment agent applied to the garment has been neutralized byan exhausted volume of dyestuff, an exemplary method of dyeing apatterned garment may further comprise, at block 409, applying a secondcationic treatment agent layer to the patterned garment. In variousembodiments, a garment pattern may comprise one or more pattern elementsets, such as, for example, primary pattern elements, and secondarypattern elements. Each respective pattern element set subsequent to theone or more primary pattern elements may correspond to one or moresubsequent operations which mirror those described above with respect toblocks 402, 403, and 404, as described herein.

In various embodiments, a second cationic treatment agent layer maycomprise one or more volumes of cationic treatment agent applied at oneor more localized areas of the garment corresponding to each of thepattern element shapes of one or more secondary pattern elements. Invarious embodiments, each of the one or more secondary pattern elementsmay vary in pattern element shape, pattern element color, and/or patternelement depth of shade from the one or more pattern elements previouslyexposed to the dyeing operation (i.e., the “primary pattern elements”),as described above. As was described above with respect to the one ormore primary pattern elements at block 402, a volume of cationictreatment agent may be applied to one or more garment areascorresponding to the respective pattern element shapes of each of theone or more pattern elements. In various embodiments, the patternelement shapes of the one or more secondary pattern elements maycorrespond to previously untreated garment areas (i.e., those whichmaintained the original garment color throughout the dyeing operationdescribed above), or may overlap, in whole or in part, one or more ofthe one or more primary pattern elements. Applying the second cationictreatment agent layer at a garment area wherein a secondary patternelement overlaps a primary element may effectively re-charge the garmentarea, so as to affect the garment's capacity for dyestuff absorption atthat area.

At block 410, an exemplary method of dyeing a patterned garment mayfurther comprise injecting a volume of one or more concentrated liquiddyes as determined by a processor into a dyeing machine, wherein thedyeing machine is loaded with the patterned garment and is at leastpartially filled with an at least substantially clean solvent. As wasdescribed above with respect to the one or more primary pattern elementsat block 407, each volume of concentrated liquid dye may be dispensedfrom a respective dye cartridge, through a corresponding dispenseheader, and directly into a dyeing machine. In various embodiments, thepatterned garment may be present in the dyeing machine prior to the oneor more volumes of concentrated liquid dye being injected.

In various embodiments, a processor may determine the extent to whicheach of the concentrated liquid dyes will be dispensed into the dyeingmachine in order to produce a pattern element color of the one of moresecondary pattern elements as selected by the user. In variousembodiments, the pattern element color of the one or more secondaryelements may different than the pattern color of the one or more primarypattern elements. In such a circumstance, where a secondary patternelement overlaps a primary pattern element, the resultant garmentpattern color at that location on the patterned garment may comprise acombination of the pattern colors of the primary and secondary patternelements. In various embodiments, as described herein, such an exemplaryprocessor determination may comprise two components: the percentageallocation of the respective concentrated liquid dye colors dispensedinto the dyeing machine and the volume of the total collectiveconcentrated liquid dye to be dispensed.

At block 411, an exemplary method of dyeing a patterned garment mayfurther comprise dyeing the patterned garment until at leastsubstantially all of the second cationic treatment agent layer has beenneutralized by an exhausted volume of dyestuff. As was described abovewith respect to the one or more primary pattern elements at block 404,at least substantially all of a volume of dyestuff absorbed by thepatterned garment may be absorbed by the one or more secondary patternelements of the garment to which the second cationic treatment agentlayer was applied. The cationized garment areas defined by the patternelement shapes of the one or more secondary pattern elements maycontinue to absorb dyestuff until their respective electric charge hasbeen neutralized. Accordingly, a neutral garment area without anelectric charge, such as, for example, an untreated (i.e.,non-cationized) garment area or a garment area that has absorbed avolume of dyestuff such that it has become neutralized, may absorb arelatively insignificant amount of dyestuff (i.e., little to nodyestuff) in comparison to the one or more cationized secondary patternelements of the garment. Untreated garment areas, as well as thosegarment areas corresponding to the, now neutralized, one or more primarypattern elements, may at least substantially maintain the color whichthey exhibited prior to the second dye cycle (i.e., the original,un-dyed garment color and the pattern element color of the one or moreprimary pattern elements) throughout the second dyeing operation. Uponneutralization of each of the garment areas cationized by the secondcationic treatment agent layer, the one or more secondary patternelements of the garment pattern may each exhibit a pattern element colorcorresponding, at least in part, to the color of the volume of dyestuffused in the second dyeing operation and a pattern element depth of shadethat is at least substantially proportional to the respective cationicconcentration of the secondary pattern element, as described herein. Thevariance in color and depth of shade between untreated garment areas,the one or more primary pattern elements, and the one or more secondarypattern elements, as well as the variance amongst each of the respectivesets of pattern elements, as described herein, creates an overallgarment aesthetic which may define the garment pattern of the patternedgarment.

In various embodiments, the patterned garment may be subsequently washedand/or dried after the second dye cycle has concluded. The garment maybe subsequently washed and/or dried using either the dyeing machine orany other suitable machine configured to wash and/or dry the garment asdescribed herein.

Exemplary Operations

FIGS. 5A-9 illustrate various exemplary patterned garments produced inaccordance with various exemplary methods as discussed herein. It shouldbe understood that the various exemplary patterned garments illustratedin FIGS. 5A-9 are disclosed herein as exemplary products of one or moremethods for dyeing a patterned garment as disclosed herein; they are inno way intended to act limiting examples or represent the full breadthof patterned garment configurations that may be produced by the presentinvention.

In various embodiments, a garment pattern instruction may be receivedwhich corresponds to a garment pattern. The garment pattern may compriseone or more pattern elements, each of which may comprise a desiredpattern element shape, desired pattern element color, and desiredpattern element depth of shade. The garment pattern may comprise one ormore sets of pattern elements, each set of pattern elements comprisingone or more pattern elements. In various embodiments, the garmentpattern may comprise an enterprise-designed pattern, a customizedpattern designed by a user (e.g., an enterprise customer), or acombination of the two.

i. First Exemplary Operation

In various embodiments, a volume of cationic treatment agent may beapplied at one or more localized areas of a garment corresponding toeach of the one or more pattern element shapes of the one or morepattern elements.

As illustrated in FIG. 5A, garment pattern instructions may be receivedwhich correspond to first garment pattern 510. As shown, the firstgarment pattern 510 comprises a first pattern element 511, a secondpattern element 512, and a third pattern element 513. The first, second,and third pattern elements may comprise a first pattern element shape, asecond pattern element shape, and a third pattern element shape,respectively. In various embodiments, a volume of cationic treatmentagent may be applied at a first cationic garment area 511, a secondcationic garment area 512, and a third cationic garment area 513, whichmay correspond, respectively, to the first, second, and third patternelement shapes. In various embodiments, the volume of cationic treatmentagent applied to each of the cationized garment areas 511, 512, 513 maybe sufficiently large so as to enable a level of dyestuff absorptionthat produces a full pattern element depth of shade. Further, in variousembodiments, the cationic concentration of each of the cationizedgarment areas 511, 512, 513 may be selectively varied, as describedherein, to affect the respective pattern element depths of shade of thefirst, second, and third pattern elements. As non-limiting examples, thefirst garment pattern 510 may comprise shapes, letters, numbers, images,graphics, and/or the like, as well as any combination thereof.

As illustrated in FIG. 5B, garment pattern instructions may be receivedwhich correspond to a second garment pattern 520. As shown, the secondgarment pattern 520 comprises a pattern element 521, which comprises apattern element shape. In the illustrated embodiment of FIG. 5B, thepattern element shape is a graphic comprising an “RL” logo. In variousembodiments, a volume of cationic treatment agent may be applied at thecationic garment area 521 which may correspond to the pattern elementshape of the pattern element 521. As a non-limiting example, the secondgarment pattern 520 may comprise a logo or any other image, which may beassociated with an enterprise such as, for example, a business,institution, organization, and/or the like.

ii. Second Exemplary Operation

A garment comprising one or more pre-treated cationized garment areasmay be dyed such that the one or more pre-treated cationized garmentareas interact with a volume of dyestuff to create the one or morepattern elements of the garment pattern.

As illustrated in FIG. 6A, the first garment pattern 610 corresponds tothe first garment pattern illustrated in FIG. 5A. As shown, the firstgarment pattern 610 comprises a first pattern element 611, a secondpattern element 612, and a third pattern element 613. The first, second,and third pattern elements 611, 612, 613 may comprise a first patternelement shape, a second pattern element shape, and a third patternelement shape, respectively, which may correspond to the firstcationized garment area 511, the second cationized garment area 512, andthe third cationized garment area 513, as illustrated in FIG. 5A. Asdescribed herein, during a dyeing operation, the first, second, andthird pattern elements 611, 612, 613 may each absorb a volume ofdyestuff. In various embodiments, due at least in part to thecationization of the garment areas corresponding to the first second,and third pattern element shapes, at least substantially all of a volumeof dyestuff absorbed by the garment during a dyeing operation isabsorbed by the first, second, and third pattern elements 611, 612, 613,collectively, while the untreated garment areas maintain the originalgarment color. Based on user input, the volume of dyestuff utilizedduring the dyeing operation may be configured to produce a patternelement comprising a particular pattern element color. Each of thepattern elements 611, 612, 613 comprise the particular pattern elementcolor corresponding to the volume of dyestuff utilized during the dyeingoperation.

As described herein, the extent to which a pattern element absorbs avolume of dyestuff, and thus, the pattern element depth of shade of thepattern element, may be affected by three depth of shade inputvariables: the volume of dyestuff used in a dye cycle, the dye cycleruntime, and the concentration of cationic treatment agent applied atthe garment area (“cationic concentration”). In various embodiments, acationic concentration of 100% should be understood to be the minimumcationic concentration required to achieve a full pattern element depthof color. In various embodiments, a dyestuff volume of 100% should beunderstood to be the maximum amount of dyestuff an area particulargarment area is physically capable of absorbing under a given set of dyecycle operating conditions, assuming a cationic concentration of 100%,as described herein. Further, in various embodiments, a dye cycleruntime of 100% should be understood to be the minimum amount of time itwould take to achieve a full pattern element depth of color given acationic concentration of 100% and a dyestuff volume of 100% under agiven set of dye cycle operating conditions. For example, as illustratedin FIG. 6A the first pattern element 611, the second pattern element,612, and the third pattern element 613 may each comprise a depth ofshade of approximately 100%. In one exemplary embodiment, the dye cycleruntime and the dyestuff volume, as described herein, may each be 100%and the pattern elements 611, 612, and 613 may each comprise a cationicconcentration of 100%.

In various embodiments, as described herein, one or more of theaforementioned depth of shade input variables may be selectively varied,alone or in combination, to achieve a desired pattern element depth ofshade. For example, using the exemplary pattern elements illustrated inin FIG. 6A, the first pattern element 611, the second pattern element,612, and the third pattern element 613 may each comprise a depth ofshade of approximately 50%. In an exemplary embodiment, each patternelement 611, 612, and 613 may comprise a cationic concentration of 50%.That is, the volume of cationic treatment agent applied to each of thecationized garment areas corresponding to the first, second, and thirdpattern element shapes is 50% of the theoretical volume of cationictreatment agent that would allow for the garment areas to absorb amaximum volume of dyestuff. The selectively reduced cationicconcentration of 50% chemically creates an absorption threshold for eachof the pattern elements 611, 612, and 613 that is 50% less than thegarment is physically capable of absorbing. Accordingly, despite a dyecycle runtime and a volume of dyestuff utilized in the dyeing operationthat would typically be sufficient to produce a full depth of shade, thepattern element depth of shade of each of the pattern elements 611, 612,613 may only rise to be 50% of the full depth of shade. In variousembodiments, the respective cationic concentrations of the first,second, and third pattern elements may vary from one another. In such acircumstance, the pattern element depth of shade of at least one of thepattern elements may be different from that of at least one of the otherpattern elements of the garment pattern.

As illustrated in FIG. 6B, a second garment pattern 620 corresponds tothe exemplary garment pattern illustrated in FIG. 5B. As shown, thesecond garment pattern 620 comprises a pattern element 621, whichcomprises a pattern element shape corresponding to the cationizedgarment area 521, as illustrated in FIG. 5B. As described herein, due atleast in part to the cationization of the garment area corresponding tothe pattern element shapes, at least substantially all of a volume ofdyestuff absorbed by the garment during a dyeing operation is absorbedby the pattern element 621, while the untreated garment areas maintainthe original garment color. Based on user input, the volume of dyestuffutilized during the dyeing operation may be configured to produce apattern element comprising a particular pattern element color. Thepattern element 621 may comprise the particular pattern element colorcorresponding to the volume of dyestuff utilized during the dyeingoperation. As illustrated in FIG. 6B, pattern element 621 may comprise apattern element depth of shade of approximately 100%. In one exemplaryembodiment, the dye cycle runtime and the dyestuff volume, as describedherein, may each be 100% and the pattern element 621 may comprise acationic concentration of 100%.

In various embodiments, as described herein, one or more of theaforementioned depth of shade input variables may be selectively varied,alone or in combination, to achieve a desired pattern element depth ofshade. For example, using the exemplary pattern element illustrated inin FIG. 6B, the cycle runtime may be selectively reduced to 50%, whilethe dyestuff volume and the cationic concentration of the patternelement 621 may each be 100%. In such an exemplary circumstance, the dyecycle runtime may be half the amount of time it would take to achieve afull pattern element depth of color under a given set of dye cycleoperating conditions. As described herein, the pattern element depth ofshade of pattern element 621 will be less than 100% (e.g., 50%), causingthe pattern element 621 to appear fainter than it would under similarcircumstances with a dye cycle runtime of 100%.

As a further non-limiting example, once again using the exemplarypattern element illustrated in in FIG. 6B, the depth of shade of patternelement 621 may be reduced by selectively reducing the dyestuff volumeto 50%, as described herein, while the dye cycle runtime and thecationic concentration of the pattern element 621 are each maintained at100%. In such an exemplary circumstance, the dyestuff volume utilized inthe dyeing operation may be half the volume that it would take toachieve a full pattern element depth of color, under a given set of dyecycle operating conditions. As a result, the pattern element depth ofshade of pattern element 621 will be less than 100% (e.g., 50%), causingthe pattern element 621 to appear fainter than it would under similarcircumstances with a dyestuff volume of 100%.

iii. Third Exemplary Operation

As illustrated in FIG. 7A, the garment pattern 700 corresponds to thefirst garment pattern illustrated in FIG. 5A. In various embodiments,garment pattern 700 may comprise a first set of pattern elements 710. Asshown, the first set of pattern elements 710 comprises a first patternelement 711, a second pattern element 712, and a third pattern element713. The first, second, and third pattern elements 711, 712, 713 maycomprise a first pattern element shape, a second pattern element shape,and a third pattern element shape, respectively, which may correspond tothe first cationized garment area 511, the second cationized garmentarea 512, and the third cationized garment area 513, as illustrated inFIG. 5A. As described herein, during a first dyeing operation, thefirst, second, and third pattern elements 711, 712, 713 may each absorba volume of dyestuff. In various embodiments, due at least in part tothe cationization of the garment areas corresponding to the firstsecond, and third pattern element shapes, at least substantially all ofa volume of dyestuff absorbed by the garment during a dyeing operationis absorbed by the first, second, and third pattern elements 711, 712,713, collectively, while the untreated garment areas maintain theoriginal garment color.

In various embodiments, the garment may be dyed until at leastsubstantially all of the applied cationic treatment agent has beenneutralized by an exhausted volume of dyestuff, as described herein. Insuch a circumstance, a garment may undergo a second dyeing operation,which may comprise applying a second cationic treatment agent layer tothe patterned garment, injecting a volume of one or more concentratedliquid dyes—each comprising a volume of dyestuff—and dyeing thepatterned garment until at least substantially all of the secondcationic treatment agent layer has been neutralized by an exhaustedvolume of dyestuff. In various embodiments, the volume of dyestuffutilized in the second dyeing operation may correspond to a secondarypattern element color, which may comprise the pattern element color of asecond set of pattern elements. As illustrated in FIG. 7B, the garmentpattern 700 may further comprise a second set of pattern elements 720.As shown, the second set of pattern elements 720 comprises a patternelement 721, which comprises a pattern element shape corresponding tothe cationized garment area 521, as illustrated in FIG. 5B. As describedherein, due at least in part to the cationization of the garment areacorresponding to the pattern element shape of pattern element 721, atleast substantially all of a volume of dyestuff absorbed by the garmentduring a second dyeing operation is absorbed by the pattern element 721.The pattern element 721 may comprise the particular pattern elementcolor corresponding to the volume of dyestuff utilized during the seconddyeing operation. As shown in FIG. 7B, the first set of pattern elements710 and the second set of pattern elements 720 may comprise differentpattern element colors, such that the garment pattern 700 may be amulti-colored pattern. In various embodiments, the pattern element size,pattern element color, and/or and pattern element depth of shade of eachof the pattern elements of the garment pattern 700 may be selected by auser and/or selectively modified as described herein.

As a further example, FIG. 8 shows an experimental garment comprisinggarment pattern 800. As shown, garment pattern 800 comprises both afirst set of pattern elements 810 and a second set of pattern elements820. Both the first and the second sets of pattern elements comprise aplurality of pattern elements, each of which comprises a respectivepattern element shape, pattern element color, and pattern element depthof shade.

Garment pattern 800 was produced by first selectively applying variousvolumes of cationic treatment agent to various garment areas via ahand-spraying application method (the garment areas corresponding to thefirst set of pattern elements 810). The exemplary garment was then curedand subsequently exposed to a first dyeing operation, wherein a volumeof dyestuff corresponding to a red garment output color was injectedinto a dyeing machine via a volume of concentrated liquid dye. The firstdyeing operation was executed until at least substantially all of theapplied cationic treatment agent had been neutralized by an exhaustedvolume of dyestuff, as described herein, so as to produce a garmentpattern comprising the first set of pattern elements 810. As shown inFIG. 8 , each of the pattern elements of the first set of patternelements 810 comprises a red pattern element color, with the respectivedepth of shade of each of the pattern elements the varying based on thecationic concentration of the garment area corresponding to the patternelement shape of each pattern element.

The second set of pattern elements 820 was subsequently added at to thegarment pattern 800 via a second dyeing operation. Once again, variousvolumes of cationic treatment agent were selectively applied—on top ofthe first set of pattern elements—to various garment areas(corresponding to the second set of pattern elements 820) via ahand-spraying application method. The exemplary garment was then curedand subsequently exposed to a second dyeing operation, wherein a volumeof dyestuff corresponding to a yellow garment output color was injectedinto a dyeing machine at least partially filled with a substantiallyclean solvent. The second dyeing operation was executed until at leastsubstantially all of the cationic treatment agent applied on top of thefirst set of pattern elements had been neutralized by an exhaustedvolume of dyestuff, as described herein. As shown, the repetition of thedyeing operations using different dyestuff corresponding to differentgarment output colors enables the garment pattern 800 to be configuredas a multi-colored garment pattern comprising both the first set ofpattern elements 810 and the second set of pattern elements 820.

iv. Fourth Exemplary Operation

As illustrated in FIG. 9 , the first garment pattern 910 corresponds tothe first garment pattern illustrated in FIG. 5A. As shown, the firstgarment pattern 910 comprises a first pattern element 911, a secondpattern element 912, and a third pattern element 913. The first, second,and third pattern elements 911, 912, 913 may comprise a first patternelement shape, a second pattern element shape, and a third patternelement shape, respectively, which may correspond to the firstcationized garment area 511, the second cationized garment area 512, andthe third cationized garment area 513, as illustrated in FIG. 5A. Asdiscussed herein, the cationic treatment agent may be selectivelyapplied to the garment using various application apparatuses andmethods. For example, as illustrated in FIG. 10 , the first patternelement 911 and the second pattern element 912 may each correspond to acationized garment area to which a volume of cationic treatment agentwas applied using a manual spraying process, such as, for example, handspraying. Further, as illustrated, the third pattern element 913 maycorrespond to a cationized garment area to which a volume of cationictreatment agent was applied using an automatic spraying process, suchas, for example, using an ink jet printer. In such a circumstance, thevolume of cationic treatment agent may be applied to a garment area asan array of substantially small localized concentrations, which, whensubjected to s subsequent dyeing process, may collectively correspond apattern element. In various embodiments, each volume of cationictreatment agent applied to the one or more cationized garment areas maybe applied using either the same or different application apparatusesand/or methods, as described herein.

As described herein, during a dyeing operation, the first, second, andthird pattern elements 911, 912, 913 may each absorb a volume ofdyestuff. In various embodiments, due at least in part to thecationization of the garment areas corresponding to the first second,and third pattern element shapes, at least substantially all of a volumeof dyestuff absorbed by the garment during a dyeing operation isabsorbed by the first, second, and third pattern elements 911, 912, 913,collectively, while the untreated garment areas maintain the originalgarment color. Based on user input, the volume of dyestuff utilizedduring the dyeing operation may be configured to produce a patternelement comprising a particular pattern element color. Each of thepattern elements 911, 912, 913 comprise the particular pattern elementcolor corresponding to the volume of dyestuff utilized during the dyeingoperation.

As illustrated in FIG. 9 , the first pattern element 911, the secondpattern element, 912, and the third pattern element 913 may eachcomprise a gradient depth of shade wherein the respective depth of shadepercentages progressively decrease across at least a portion of eachpattern element. In one exemplary embodiment, the dye cycle runtime andthe dyestuff volume, as described herein, may each be 100% and thepattern elements 911, 912, and 913 may each comprise a gradient cationicconcentration. As shown, the first and third pattern elements 911, 913each comprise a linearly gradient depth of shade, while the secondpattern element 912 comprises a radially gradient depth of shade. Asdiscussed herein, a pattern element depth of shade which graduallytransitions from a fuller depth of shade to a lesser depth of shade in afirst direction across a portion of the pattern element may correspondto a gradient cationic concentration which progressively decreases inthe first direction across the garment area corresponding to the patternelement. Such a gradient pattern element depth of shade may be desirableto avoid distinct depth of shade variances. It should be understood thata pattern element may comprise a gradient depth of shade of any shape,intensity, and/or directional configuration.

CONCLUSION

Many modifications and other embodiments will come to mind to oneskilled in the art to which this disclosure pertains having the benefitof the teachings presented in the foregoing descriptions and theassociated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedand that modifications and other embodiments are intended to be includedwithin the scope of the appended claims. Although specific terms areemployed herein, they are used in a generic and descriptive sense onlyand not for purposes of limitation.

That which is claimed:
 1. An apparatus for dyeing garments, theapparatus comprising: a dye injection system configured to dispenseconcentrated liquid dye; a dyeing machine comprising a dyeing chamberconfigured for dyeing at least one garment in a dyebath, wherein thedyebath comprises the concentrated liquid dye received from the dyeinjection system and a volume of solvent; and a controller incommunication with the dye injection system and the dyeing machine,wherein the controller is configured to: receive at least one garmentparameter corresponding to the at least one garment; based at least inpart on the at least one received garment parameter, cause the dyeinjection system to dispense a volume of concentrated liquid dye thatcontains an amount of dyestuff that can be substantially absorbed by theat least one garment; and cause the dyeing machine to execute a dyecycle such that substantially all of the dyestuff in the dispensedvolume of concentrated liquid dye is absorbed by the at least onegarment within the dyeing chamber; wherein the dyeing machine isconfigured to maintain at least a portion of the volume of solventwithin a substantially closed-loop system for reuse in a subsequent dyecycle.
 2. The apparatus of claim 1, comprising the dyebath, wherein thedyebath within the dyeing chamber is substantially free of SodiumChloride, Sodium Sulphate, and alkaline content throughout the dyecycle.
 3. The apparatus of claim 1, wherein the dyeing machine isconfigured to execute the dye cycle with the dyebath at substantiallyambient room temperature.
 4. The apparatus of claim 1, wherein the atleast one garment parameter comprises a weight of the at least onegarment.
 5. The apparatus of claim 4, further comprising a weightsensor; and wherein the controller is further configured to receive theweight of the at least one garment from the weight sensor.
 6. Theapparatus of claim 1, further comprising at least one holding tank influid communication with the dyeing chamber, wherein the at least oneholding tank is configured for holding the volume of solvent in betweendyeing cycles.
 7. The apparatus of claim 2, wherein the dyebathcomprises the volume of solvent, the volume of solvent comprising water.8. The apparatus of claim 2, wherein the dyebath comprises theconcentrated liquid dye, the concentrated liquid dye comprising dyestuffand water.
 9. The apparatus of claim 8, wherein the plurality ofconcentrated liquid dye cartridges of the dye injection system comprisesbetween seven and twelve concentrated liquid dye cartridges.
 10. Theapparatus of claim 1, wherein the controller is further configured tocause the dye injection system to dispense the volume of concentratedliquid dye that contains the amount of dyestuff that can besubstantially absorbed by the at least one garment based at least inpart on the user-selected desired garment color.
 11. The apparatus ofclaim 1, wherein the controller is further configured to, based at leastin part on a user-selected desired garment color, cause one or more of aplurality of concentrated liquid dye cartridges to dispense concentratedliquid dye into the dyeing chamber to produce the user-selected desiredgarment color during the dye cycle.
 12. The apparatus of claim 11,further comprising a user interface configured to enable a user toselect the desired garment color.
 13. The apparatus of claim 1, whereinthe dispensed volume of concentrated liquid dye contains an amount ofdyestuff that is substantially less than or equal to a dyestuffabsorption capacity of the at least one garment.